Specs 2019 V2

GOVERNMENT OF INDIA
CENTRAL PUBLIC WORKS DEPARTMENT
SPECIFICATIONS
(VOL. 2)
2019
Published under the Authority of Director General, CPWD, New Delhi

© All rights reserved. No part of this publication may be reproduced in any form or by any means,
electronic or mechanical, including photocopying, recording on any information storage and retrieval
system, without permission, in writing, from the Director General, CPWD, New Delhi. Photocopying
of this book is strictly prohibited.
For feed back and suggestions, please contact SE(TAS), CPWD, Room No. 418, ''A'' Wing,
Nirman Bhawan, New Delhi. Tel. No. 011-23062339, Email: delsetascsq.cpwd@nic.in
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Price : Rs. 2500/- (for both volumes) excluding postage and forwarding charges etc.
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Government of India fuekZ.k Hkou] ubZ fnYyh 110011
Central Public Works Department
PRABHAKAR SINGH Nirman Bhawan, New Delhi- 110011
Director General Tel : 23062556 / 1317, Fax : 23061884
E-Mail : cpwd_dgw@nic.in
The CPWD Specifications being published by CPWD from time to time are very
comprehensive and useful in execution of works and are used as guide by a number
of Engineering Departments, Public Sector Undertakings, Architects and Builders.
These specifications not only give the standards for building materials but also serve
as guidelines for execution of works, measurements and rates.
The CPWD Specifications were first compiled in 1950. Subsequently, these

specifications have been revised in the years 1962, 1967, 1977, 1996 and 2009
Many new items and construction technologies, which are used in various
CPWD works and projects have been incorporated in Delhi Schedule of Rates of
CPWD. Some items have become obsolete over a period of time and are not in use.
Further, there were no specifications for Rain Water Harvesting & Tubewells,
Conservation of Heritage Buildings, Structural Glazing Aluminium Composite Panel
and New Technologies & Materials. CPWD Specifications have been accordingly
modified/ revised and updated to incorporate the above changes.
The revised/updated specifications are being published in two volumes.
I wish to place on record the effective coordination on the part of Dr. K. M. Soni,
ADG (Tech.) and the technical inputs and the efforts by Sh. M. K. Mallick, CE
(CSQ), Sh. Divakar Agrawal, SE(TAS), Sh. Satya Narain Jaiswal, EE(TAS-I),
Sh. Moti Lal Prasad (TAS-II), Sh. D.S. Adhikari, AE(QA), Sh. Naveenkumar P, JE
and Sh. Chalapaka Ramaraju, JE and all others officers of CSQ in finalizing these
specifications.
I am sure that these Specifications will be useful to all concerned in the

building industry in general and CPWD in particular.
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Government of India
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DR K.M. SONI fuekZ.k Hkou] ubZ fnYyh 110011
Central Public Works Department
Additional Director General (Tech)
Nirman Bhawan, New Delhi- 110011
PREFACE
1.0 CPWD Specifications, 2019 are the revised edition of existing CPWD Specifications.
2.0 CPWD Specifications, 2019 is published in two volumes as under:
Volume Sub-head No. Contents/ Chapters

Number
1 0.0 General
1.0 Carriage of Materials
2.0 Earth Work
3.0 Mortars
4.0 Concrete Work
5.0 Reinforced Cement Concrete Work
6.0 Masonary work
7.0 Stone Work
8.0 Cladding work
9.0 Wood Work and PVC Work
10.0 Steel Work
11.0 Flooring
12.0 Roofing
2 13.0 Finishing
14.0 Repairs to Buildings
15.0 Dismantling and Demolishing
16.0 Road Work
17.0 Sanitary Installation
18.0 Water Supply
19.0 Drainage
20.0 Pile Work
21.0 Aluminium Work
22.0 Water Proofing
(v)
23.0 Rain Water Harvesting & Tubewells
24.0 Conservation of Heritage Buildings
25.0 Structural Glazing Aluminum Composite Panel
26.0 New Technologies and Materials
3.0 CPWD Specifications, 2019 will replace existing CPWD Specifications, 2009 along with correction slips. The
specifications of many items have been updated and improved by making them more comprehensive. Specifications
of items, which have become obsolete over a period of time or are not in use, have been deleted. Many new items
using new materials and latest technology have also been added.
4.0 Specifications of dry work for speedier construction using prefabricated materials and pre-finished elements
are included viz gypsum block walls, calcium silicate and non-asbestos cement board partitions, pre-finished
counter tops for kitchen and washbasins, pre-moulded and pre-finished stone work in risers and treads of steps
and window sills, dry stone cladding, sub-frames for windows, use of chemical and mechanical fasteners, laying
of tiles in flooring and dado with polymer based adhesives etc.
5.0 Specifications of Rain Water Harvesting & Tubewells, Conservation of Heritage Building, Structural
Glazing Aluminium Composite Panel and New Technologies & Materials are incorporated for the first time.
6.0 Sub-head wise salient features are as follows:
6.1 Earth Work : Specifications for filling with available fly ash and Earth (excluding rock) have been
incorporated. The clause no 2.22 has been deleted.
6.2 Concrete : Specifications of aggregate from other than natural resources shall comply with requirement
of IS 383:2016 have been introduced.
6.3 Reinforced Cement Concrete : Specifications of steel reinforcement for R.C.C. work ready to use
“Cut and bend rebars, Reinforcement couplers, Precast door & window frames, Expansion joint covering with
cement bonded particle board, Expansion joint covering with stainless steel grade 304, RCC for construction
of piers, abutment, portal frame, pier caps, bearing pedestals & seismic arresters, RCC diaphragm wall and
Expansion joint system for floor, wall & roof joint have been incorporated. Guidelines for multistage centering
also introduced in this sub head.
6.4 Masonry Work : Specifications of AAC block masonry have been incorporated. The name of sub head
Brick work has been renamed as Masonry work.
6.5 Stone Work : Specifications of stone work in or under water and /or in liquid mud & under foul position
have been incorporated. The specification Clause No. 7.7 Shifted to Sub Head 8 (Cladding work) Under
Clause No. 8.8, Clause No. 7.11,7.12 & 7.13 are shifted to Sub Head 8 (Cladding work) under clause No. 8.12,
8.13 & 8.14. Figures 7.14, 7.15 & 7.16 shifted to Sub head 8 (cladding work) under Fig. 8.5, 8.6 & 8.7.
6.6 Cladding Work : Specifications of wall lining butch work with Dholpur stone, Kota stone veneering
work, Extra for stone work for wall lining, veneered decorative plywood, Air veneer board for general purposes,
prelaminated particle board, laminated sandwiched composite panel cladding system and associated works
have been incorporated. The name of Sub Head has been renamed as Cladding work from Marble work.
6.7 Wood Work and PVC Work : Specifications for cupboard shutter, lipping in pelmet, teak wood lipping,
uPVC casement/sliding window & door and Fire resistant glazed doors, windows & partition have been incorporated.
Fig. 9.29 to 9.39 have been added. The specification Clause No. 9.9 shifted to Sub Head 8 (cladding work) under
clause No. 8.15. Specification of Nickel plated M.S. Pipe curtain roads, M.S. grills in frames of window, Bamboo
Jaffery/ fencing, wooden moulded corner beading, magnetic catchers, powder coated telescopic drawer channel,
slidling arrangement in racks/ cupboards/ cabinets shutter, hardware fittings for uPVC door/ windows, pre-
laminated medium density fibre board and stainless handles have been incorporated.
(vi)
6.8 Steel work : Specifications of dash fasteners, stainless steel railing, Fly proof wire gauze, Glass
panes with putty and Glazing clips, Angle iron frames for doors, windows and ventilators have been incorporated.
6.9 Flooring : Specifications of pendulum test for skid resistance, Turf paver, Border tiles, Epoxy based
grouting for tiles, Italian marble stone flooring and flamed finish granite stone flooring have been incorporated.
6.10 Finishing : Specifications of White cement based polymer modified mortar, 1st quality distemper
for new & old works, Deluxe multi surface paint for interior and exterior, Epoxy Paint, Fire Retardant
Paint, G.I. metal tiles ceiling, Heat resistant terrace floor, thermal insulations over existing wall with fiber
glass wool, calcium silicate tiles false ceiling, calcium silicate board false ceiling, thermal insulation of
ceiling, thermal insulation over existing false ceiling, thermal insulation over existing wall and Melamine
Polish have been incorporated.
6.11 Repairs to building: Specifications of fixing old wind ties, Brick work in mud mortar, Brass curtain
roads, fixing MS round or square bars in wooden frame of window, Wooden karries for roofing, Double Scaffolding
system upto seven storey height made with MS tube, Repairs to plaster in patches, Cleaning of water storage
tanks, Disconnecting damaged over head/terrace, Replacement of old damaged WC seats, Cutting holes of
required size in brick masonry wall, Dismantling of WC pan of all sizes, Hacking of C.C. flooring, Dismantling of
15 mm to 40 mm dia G.I. pipe, Taking out existing wooden door shutter and refixing the same after repairs,
Security guard without gun and Security guard with gun have been incorporated. The specification clause no.
14.19, 14.20, 14.21, 14.22, 14.24, 14.25, 14.26, 14.28, 14.29, 14.30 & 14.32 are shifted to Sub Head:- 13
(Finishing) under clause no. 13.14, 13.18, 13.19, 13.21, 13.44, 13.45, 13.46, 13.47, 13.48, 13.35, 13.40 respectively.
6.12 Road Work: Specifications of Granular sub base, Wet Mix Macadam (WMM) sub-base/base, Reflective
Pavement Markers (RPM) or road studs and Prime coat over granular base have been incorporated. Specification
of tack coat with bitumen emulsion has been modified.
6.13 Sanitary Installations: Specifications of Hubbles centrifugally cast (spun) iron pipes and fittings,
Installation of sink, cutting chase in masonry wall, painting synthetic enamel paint on SCI/ centrifugally cast
(spun) iron soil, waste and vent Pipe, Repainting SCI/ Centrifugally cast (spun) iron soil, Waste and vent Pipe,
Installation of wall mounted water closet (WC) and Installation of floor mounted single piece water closet (WC)
have been incorporated.
6.14 Water Supply : Specifications of CP brass bib cock, CP brass long nose bib cock, CP brass long
body bib cock, CP brass stop cock, CP brass angle value, CP brass extension nipple, PTMT bib cock, PTMT
stop cock, PTMT pillar cock, PTMT push cock, PTMT grating, PTMT ball cock, PTMT angle stop cock, PVC
connection pipe, PTMT extension nipple for water tank pipe, Disinfection C.I. water mains by flushing with
water and chrome plated brass battery based infrared sensor operated pillar cock have been introduced.
6.15 Drainage: Specifications of dismantling of old S.W. pipes, 6 mm thick plastic encapsulated MS foot
rest, Replacement of MS foot rest in manholes, Raising of manhole cover and frame slab, Inspection chamber,
Non pressure NP-3 class (medium duty)/NP-4 class (Heavy duty) RCC pipes have been incorporated. Fig
19.19 to Fig. 19.22 have been incorporated.
6.16 Aluminium Work: Specifications of Machine moulded aluminium covering over expansion, Anodized
aluminium grill, 12mm thick frameless toughened glass door shutter and Non sag elastomeric polyurethane
sealant have been incorporated.
6.17 Water Proofing: Specifications of Water proofing treatment with Integral crystalline admixture, Fibre
reinforced elastomeric liquid water proofing membrane having Sun Reflectivity Index (SRI) of 105, Water
proofing treatment with integral crystalline water proofing coating/slurry, Flexible cementatious negative side
water proofing coating with elastic water proofing polymers, Water proofing treatment with integral crystalline
water proofing dry-shake, Crystalline water proofing mortar and Swellable type water stop tape have been
incorporated. The specification clause no. 22.12, 22.13 & 22.14 shifted to sub head 14 (Repairs to Buildings)
under clause no. 14.49, 14.50 & 14.51 respectively. Fig. 22.11 & 22.12 shifted to sub head 14 (repairs to
buildings) under Fig. 14.10 & 14.11 respectively.
(vii)
6.18 Rain Water Harvesting & Tubewells: New sub head has been introduced and all Specifications kept
in this sub head are new specifications.
6.19 Conservation of heritage building: New sub head has been introduced and all specifications kept in
this sub head are new specifications.
6.20 Structural glazing aluminium composite panel: New sub head has been introduced and all
specifications kept in this sub head are new specifications.
6.21 New Technologies and materials: New sub head has been introduced and all specifications kept in
this sub head are new specifications.
7.0. A lot of effort has gone into the preparation of CPWD Specifications, 2019. I convey my deep appreciation
and sincere thanks to Sh. M. K. Mallick, CE(CSQ), Sh. Divakar Agrawal, SE(TAS), Sh. Satya Narain Jaiswal,
EE(TAS-I), Sh. Moti Lal Prasad, EE(TAS-II), Sh. P. Goyal, EE(TAD), Sh. A. K. Sikka, EE(Con.),
Sh. M.C. Singhal, EE(QA), Sh. Shivani Kaushal, EE (M), Sh. D.S. Adhikari, AE(QA), Sh. Patta Madhukumar
AE (TAS), Sh. Sanjay Singh, AE(TAS), Sh. Jitender Kumar Tiwari, AE(TAS), Sh. Mohammad Tarik AE(QA),
Sh. S. K. Sharma, AE(QA), Sh. N. N. Sharma, AE(QA), Sh. K.R. Meena, AE(Con.), Sh. R. K. Sharma,
AE(Con.), Sh. S. K. Roy AE(M), Sh. P.K. Upreti, AE(M), Sh. P.K. Verma, AE(TAS), Sh. Gurmeet Singh,
AE(TAD), Sh. Ved Khurana, AE(TLC), Sh. Jai Bhagwan, AE(TAS), Sh. Chalapaka Ramaraju, JE(TAD),
Sh. Naveen kumar P., JE(TAS), Sh. Mukesh Verma, Chief Estimator (TAS) and other officers and staff of TAS
Unit for sincere efforts made in the preparation of this document in such a short time.
8.0 My sincere thanks to the specifications committee and Sh. Vimal Kumar, CE (NDZ-II),
Sh. O.P. Tripathi, CPM IITDPZ & Sh. Sanjay Singh, AE, Sh. Rajeev Singhal, CPM, NDPZ &
Sh. Sajal Mitra, EE, Sh. Umesh Bansal, SE, PEC, Sh. V.P. Srivastava, EE, PED, Sh. Manoj Kumar Thakur,
AE, PED & Sh. A. K. Grover EE(P), (NDZ)-I, Sh. Anant Kumar, CE (NZ)-V, Sh. Ujjwal Mitra, CE, (NDZ)-III,
Sh. Ujjwal Kumar, CE (NDZ)-VI, Sh. Harnam Singh, CPM, (RPZ), Sh. Pradeep Gupta, CE, (ICBRPZ),
Sh. Ramesh Chandra, CE, (NDZ)-IV, Sh. Vikas Rana, CE (NDZ)-VII & Sh. Manoj Kumar SE & Sh. Virender
Singh, EE, Sh. B. B. Makkar, CPM, SCPZ & Sh. Varun Gupta, AEE & Sh. Savinay Srivastav, AE, Sh. Mohd.
Kamal Ahmad, CE, CZ, Bhopal, Sh. L. Dung Dung, CE, (WZ-I), Mumbai, Sh. Manoj Kumar Talreja, CE,
ZEZ-II & Surender Kumar Rampal, CE & Sh. Amrender Kumar Jalan EE & Sh. Subhadip Ghosh, AE,
Sh. D.Roy Chowdhury, CPM, Sh. K.C.Singh, CE, NZ-I, Sh. N.N.S.Rao, CE, SZ-II & Sh. Mathura Prasad, CE,
PWD their teams for great help extended in preparation of this document and graphic cover desigining by
Sh. Sachin Sharma, Dy. Architect, Ms. Azra Mahwash, Architect & Ms. Roopanshi Goel, Int. Architect.
9.0 Due care has been taken to print CPWD Specifications, 2019 as correctly as possible. It is, however, possible
that some errors might have crept in inadvertently. In case any error or omission is noticed, it may be brought to the
notice of the Superintending Engineer (TAS), CPWD, Room No. 418, A- Wing, Nirman Bhawan, New Delhi.
Suggestions for improvement are welcome.
(Dr.K.M.Soni)
ADG (Tech), CPWD,
Nirman Bhawan, New Delhi
(viii)
CONTENTS
Vol. 2
SH. No. Name of Sub-Head Page No.
13.0 FINISHING 625 – 680
14.0 REPAIRS TO BUILDINGS 681 – 730
15.0 DISMANTALING AND DEMOLISHING 731 – 744
16.0 ROAD WORK 745 – 876
17.0 SANITARY INSTALLATIONS 877 – 940
18.0 WATER SUPPLY 941 – 1008
19.0 DRAINAGE 1009 – 1074
20.0 PILE WORK 1075 – 1118
21.0 ALUMINIUM WORK 1119 – 1158
22.0 WATER PROOFING TREATMENT 1159 – 1206
23.0 RAIN WATER HARVESTING & TUBEWELLS 1207 – 1240
24.0 CONSERVATION OF HERITAGE BUILDINGS 1241 – 1256
25.0 STRUCTURAL GLAZING ALUMINIUM COMPOSITE PANEL 1257 – 1274
26.0 NEW TECHNOLOGIES AND MATERIALS 1275 – 1368
For Sub Heads 0.0 to 0.12 see Vol. 1.
(ix) CONTENTS
SUB HEAD : 13.0
FINISHING
625
CONTENTS
Clause No. Brief Description Page No.
List of Bureau of Indian Standards Codes 631
13.1 Cement Plaster 12 mm, 15 mm, or 20 mm 633
13.2 Cement Plaster with a Floating Coat of Neat Cement 636
13.3 18 mm Cement Plaster (Two Coat Work) 636
13.4 6 mm Cement Plaster on Cement Concrete and 636

Reinforced Cement Concrete Work
13.5 6 mm Cement Plaster for Slab Bearing 638
13.6 Neat Cement Punning 638
13.7 Rough Cast Plaster 639
13.8 Pebble Dash Finish (In Situ Work) 640
13.9 Plain Bands of Cement Mortar 640
13.10 Moulded Bands of Cement Mortar (Single Coat Work) 641
13.11 Moulded Bands of Cement Mortar (Two Coat Work) 641
13.12 Cement Water Proofing Compound 642
13.13 Pointing on Brick Work, Tile Work and Stone Work 642
13.13A White cement based polymer modified mortar 645
13.14 White Washing with Lime 646
13.15 Satna Lime Washing 647
13.16 White Washing with Whiting 647
13.17 Colour Washing 648
13.18 Dry Distempering 648
13.19 Oil Emulsion (Oil Bound) Washable Distempering 649
627 SUB HEAD 13.0 : FINISHING

13.19A 1st Quality Acrylic Distemper 650
13.20 Cement Primer Coat 652
13.21 Cement Paint 652
13.22 Exterior Painting on Wall 653
13.22A Deluxe multi surface paint for interiors and exteriors 654
13.23 Painting 655
13.24 Painting Priming Coat on Wood, Iron or Plastered 659

Surfaces
13.24A Epoxy Paint 661
13.25 Painting Synthetic Enamel Paint over G.S. Sheets 662
13.26 Painting Cast Iron Rain Water, Soil, Waste and Vent 663
Pipes and Fittings
13.27 Painting with Wood Preservative 663
13.27A Fire Retardant Paint 664
13.28 Coal Tarring 664
13.29 Spray Painting with Flat Wall Paint on New Surface 665
13.30 Spray Painting with Flat Wall Paint on Old Surface 665
13.31 Wall Painting with Plastic Emulsion Paint 666
13.32 Painting with Synthetic Enamel Paint 667
13.33 Painting with Aluminium Paint 668
13.34 Painting with Acid Proof Paint 668
13.35 Painting with Anti-Corrosive Bitumastic Paint 668
13.36 Floor Painting 669
13.37 Varnishing 669
CPWD SPECIFICATIONS 2019 628

13.37A Melamine Polish 671
13.38 French Spirit Polishing 671
13.39 Bees Waxing or Polishing with Readymade 672

Wax Polish
13.40 Lettering with Paint 673
13.41 Removing Old Paint 673
13.42 Washed Stone Grit Plaster 675
13.43 Gypsum Light Weight Plaster 676
13.44 Painting Cast Iron Rain Water, Soil, Waste and 677
Vent Pipes and fittings
13.45 Painting with wood preservative 677
13.46 Wall painting with plastic emulsion paint 678
13.47 Painting with synthetic enamel paint 679
13.48 Painting with aluminium paint 680

LIST OF BUREAU OF INDIAN STANDARD CODES
S. No. BIS. No. Subject

1. IS 16 (Pt-I) Shellac : Part : I - Hand Made Shellac
IS 16 (Pt-II) Shellac : Part : II - Machine Made Shellac
2. IS 75 Linseed Oil Raw and Refined
3. IS 77 Linseed Oil Boiled For Paints
4. IS 102 Ready Mixed Paint, Brushing, Red Lead, Nonsetting, Priming
5. IS 104 Specification for Ready Mixed Paint, Brushing, Zinc Chrome, Priming
6. IS 109 Ready Mixed Paint, brushing, priming Plaster to Indian Standard
Colour No.361, 631 White and off White
7. IS 117 Ready Mixed Paint, Brushing, Finishing Exterior, Semigloss for
General Purposes to Indian Standards Colours.
8. IS 133 Enamel, Interior (a) Under Coating (b) Finishing
9. IS 137 Ready Mixed Paint, Brushing, Matt Or Egg Shell Flat, Finishing Interior
to Indian Standard Colour as required
10. IS 158 Ready Mixed Paint, Brushing, Bituminous Black, Lead Free, Acid,
Alkali and Heat Resisting
11. IS 217 Specification for Cut Back Bitumen
12. IS 218 Specification for Creosote and Anthracene Oil For Use As Wood
Preservatives
13. IS 290 Coal Tar Black Paint
14. IS 337 Varnish, Finishing Interior
15. IS 341 Black Japan, Types 'A', 'B' & 'C'
16. IS 347 Varnish, Shellac for General Purposes
17. IS 348 French Polish
18. IS 419 Putty for Use On Window Frames
19. IS 427 Distemper, Dry Colour as Required
20. IS 428 Distemper, Oil Emulsion, Colour as Required
21. IS 524 Varnish, Finishing, Exterior, Synthetic Air Drying
22. IS 533 Gum Spirit of Turpentine (Oil of Turpentine)
23. IS 712 Specification For Building Limes
24. IS 1200 (Pt-XII) Method of Measurements of Building and Civil Engineering Works :
Part : XII - Plastering and Pointing
25. IS 1200 (Pt-XIII) Method of Measurements of Building and Civil Engineering Works :
Part : XIII - White Washing, Colour Washing Distempering and Painting
of Building Surfaces.

26. IS 1200 (Pt-XV) Methods of Measurements of Building and Civil Engineering Works :
Part : XV - Painting, Polishing, Varnishing etc.
27. IS 2339 Aluminium Paint For General Purposes, in Dual Container
28. IS 2547 (Pt-II) Gypsum Building Plasters Pt.II Premixed Light Weight Plasters
29. IS 2932 Enamel, Synthetic, Exterior (a) Undercoating, (b) Finishing
30. IS 2933 Enamel, Exterior (a) Undercoating (b) Finishing
31. IS 5410 Cement Paint
32. IS 5411 (Pt-1) Plastic Emulsion : Paint Part I For Interior Use
33. IS 6278 Code of Practice For White Washing and Colour Washing
34. IS 12777 Method for classification of flame spread of products

13.0 FINISHING
13.1 CEMENT PLASTER

The cement plaster shall be 12 mm, 15 mm or 20 mm thick as specified in the item.
13.1.1 Scaffolding
For all exposed brick work or tile work double scaffolding independent of the work having two sets
of vertical supports shall be provided. The supports shall be sound and strong, tied together with
horizontal pieces over which scaffolding planks shall be fixed.
For all other work in buildings, single scaffolding shall be permitted. In such cases the inner end
of the horizontal scaffolding pole shall rest in a hole provided only in the header course for the
purpose. Only one header for each pole shall be left out. Such holes for scaffolding shall, however,
not be allowed in pillars/columns less than one metre in width or immediately near the skew backs of
arches. The holes left in masonry works for scaffolding purposes shall be filled and made good
before plastering.
Note : In case of special type of brick work, scaffolding shall be got approved from Engineer-in-
charge in advance.
13.1.2 Preparation of Surface

The joints shall be raked out properly. Dust and loose mortar shall be brushed out. Efflorescence
if any shall be removed by brushing and scrapping. The surface shall then be thoroughly washed
with water, cleaned and kept wet before plastering is commenced.
In case of concrete surface if a chemical retarder has been applied to the form work, the surface
shall be roughened by wire brushing and all the resulting dust and loose particles cleaned off and
care shall be taken that none of the retarders is left on the surface.
13.1.3 Mortar
The mortar of the specified mix using the type of sand described in the item shall be used. It shall
be as specified in Subhead 3.0. For external work and under coat work, the fine aggregate shall
conform to grading IV. For finishing coat work the fine aggregate conforming to grading zone V shall
be used.
13.1.4 Application of Plaster

13.1.4.1 Ceiling plaster shall be completed before commencement of wall plaster.
13.1.4.2 Plastering shall be started from the top and worked down towards the floor. All putlog holes
shall be properly filled in advance of the plastering as the scaffolding is being taken down. To ensure
even thickness and a true surface, plaster about 15 × 15 cm shall be first applied, horizontally and
vertically, at not more than 2 metres intervals over the entire surface to serve as gauges. The surfaces
of these gauged areas shall be truly in the plane of the finished plaster surface. The mortar shall then
be laid on the wall, between the gauges with trowel. The mortar shall be applied in a uniform surface
slightly more than the specified thickness. This shall be brought to a true surface, by working a wooden
straight edge reaching across the gauges, with small upward and side ways movements at a time.
Finally the surface shall be finished off true with trowel or wooden float according as a smooth or a
sandy granular texture is required. Excessive troweling or over working the float shall be avoided.
13.1.4.3 All corners, arrises, angles and junctions shall be truly vertical or horizontal as the case may
be and shall be carefully finished. Rounding or chamfering corners, arrises, provision of grooves at
junctions etc. where required shall be done without any extra payment. Such rounding, chamfering
or grooving shall be carried out with proper templates or battens to the sizes required.

13.1.4.4 When suspending work at the end of the day, the plaster shall be left, cut clean to line both
horizontally and vertically. When recommencing the plastering, the edge of the old work shall be
scrapped cleaned and wetted with cement slurry before plaster is applied to the adjacent areas, to
enable the two to properly join together. Plastering work shall be closed at the end of the day on the
body of wall and not nearer than 15 cm to any corners or arrises. It shall not be closed on the body
of the features such as plasters, bands and cornices, nor at the corners of arrises. Horizontal joints
in plaster work shall not also occur on parapet tops and copings as these invariably lead to leakages.
The plastering and finishing shall be completed within half an hour of adding water to the dry mortar.
No portion of the surface shall be left out initially to be patched up later on. The plastering and
finishing shall be completed within half an hour of adding water to the dry mortar.
13.1.5 Thickness
Where the thickness required as per description of the item is 20 mm the average thickness of
the plaster shall not be less than 20 mm whether the wall treated is of brick or stone. In the case of
brick work, the minimum thickness over any portion of the surface shall be not less than 15 mm while
in case of stone work the minimum thickness over the bushings shall be not less than 12 mm.
13.1.6 Curing
Curing shall be started as soon as the plaster has hardened sufficiently not to be damaged when
watered.
The plaster shall be kept wet for a period of at least 7 days. During this period, it shall be suitably
protected from all damages at the contractor’s expense by such means as the Engineer-in-Charge
may approve. The dates on which the plastering is done shall be legibly marked on the various
sections plastered so that curing for the specified period thereafter can be watched.
13.1.7 Finish
The plaster shall be finished to a true and plumb surface and to the proper degree of smoothness
as required. The work shall be tested frequently as the work proceeds with a true straight edge not
less than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested with a level
and all jambs and corners with a plumb bob as the work proceeds.
13.1.8 Precaution
Any cracks which appear in the surface and all portions which sound hollow when tapped, or are
found to be soft or otherwise defective, shall be cut out in rectangular shape and redone as directed
by the Engineer-in-Charge.
(i) When ceiling plaster is done, it shall be finished to chamfered edge at an angle at its junction
with a suitable tool when plaster is being done. Similarly when the wall plaster is being done,
it shall be kept separate from the ceiling plaster by a thin straight groove not deeper than 6
mm drawn with any suitable method with the wall while the plaster is green.
(ii) To prevent surface cracks appearing between junctions of column/beam and walls, 150 mm wide
chicken wire mesh should be fixed with U nails 150 mm centre to centre before plastering the
junction. The plastering of walls and beam/column in one vertical plane should be carried out in
one go. For providing and fixing chicken wire mesh with U nails payment shall be made separately.
13.1.9 Measurements
13.1.9.1 Length and breadth shall be measured correct to a cm and its area shall be calculated in
square metres correct to two places of decimal.
13.1.9.2 Thickness of the plaster shall be exclusive of the thickness of the key i.e. grooves, or open
joints in brick work.

13.1.9.3 The measurement of wall plaster shall be taken between the walls or partitions (the dimensions
before the plaster shall be taken) for the length and from the top of the floor or skirting to the ceiling for the
height. Depth of coves or cornices if any shall be deducted.
13.1.9.4 The following shall be measured separately from wall plaster.

(a) Plaster bands 30 cm wide and under
(b) Cornice beadings and architraves or architraves moulded wholly in plaster.
(c) Circular work not exceeding 6 m in radius.
13.1.9.5 Plaster over masonry pilasters will be measured and paid for as plaster only.
13.1.9.6 A coefficient of 1.63 shall be adopted for the measurement of one side plastering on honey comb
work having 6 x 10 cm. opening.
13.1.9.7 Moulded cornices and coves.

(a) Length shall be measured at the centre of the girth.
(b) Moulded cornices and coves shall be given in square metres the area being arrived at by multiplying
length by the girth.
(c) Flat or weathered top to cornices when exceeding 15 cm in width shall not be included in the girth
but measured with the general plaster work.
(d) Cornices which are curved in their length shall be measured separately.
13.1.9.8 Exterior plastering at a height greater than 10 m from average ground level shall be measured separately
in each storey height. Patch plastering (in repairs) shall be measured as plastering new work, where the patch
exceed 2.5 sqm. extra payment being made for preparing old wall, such as dismantling old plaster, raking out the
joints and cleaning the surface. Where the patch does not exceed 2.5 sqm in area it shall be measured under the
appropriate item under sub head ‘Repairs to Buildings.’
13.1.9.9 Deductions in measurements, for opening etc. will be regulated as follows:

(a) No deduction will be made for openings or ends of joists, beams, posts, girders, steps etc. upto 0.5
sqm in area and no additions shall be made either, for the jambs, soffits and sills of such openings.
The above procedure will apply to both faces of wall.
(b) Deduction for opening exceeding 0.5 sqm but not exceeding 3 sqm each shall be made for reveals,
jambs, soffits sills, sills, etc. of these openings.
(i) When both faces of walls are plastered with same plaster, deductions shall be made for one
face only.
(ii) When two faces of walls are plastered with different types of plaster or if one face is plastered
and other is pointed or one face is plastered and other is unplastered, deduction shall be made
from the plaster or pointing on the side of the frame for the doors, windows etc. on which width
of reveals is less than that on the other side but no deduction shall be made on the other side.
Where width of reveals on both faces of wall are equal, deduction of 50% of area of opening on
each face shall be made from area of plaster and/or pointing as the case may be.
(iii) For opening having door frame equal to or projecting beyond thickness of wall, full deduction for
opening shall be made from each plastered face of wall.
(c) For opening exceeding 3 sqm in area, deduction will be made in the measurements for the full
opening of the wall treatment on both faces, while at the same time, jambs, sills and soffits will be
measured for payment.
In measuring jambs, sills and soffits, deduction shall not be made for the area in contact with the frame of
doors, windows etc.

13.1.10 Rate
The rate shall include the cost of all labour and materials involved in all the operations described
above.
13.2 CEMENT PLASTER WITH A FLOATING COAT OF NEAT CEMENT
13.2.0 The cement plaster shall be 12, 15 or 20 mm thick, finished with a floating coat of neat
cement, as described in the item.
13.2.1 Specifications for this item of work shall be same as described in 13.1 except for the additional
floating coat which shall be carried out as below.
When the plaster has been brought to a true surface with the wooden straight edge (clause
13.1.4.2) it shall be uniformly treated over its entire area with a paste of neat cement and rubbed
smooth, so that the whole surface is covered with neat cement coating. The quantity of cement
applied for floating coat shall be 1 kg per sqm. Smooth finishing shall be completed with trowel
immediately and in no case later than half an hour of adding water to the plaster mix. The rest of the
specifications described in 13.1.4 shall apply.
13.3 18 MM CEMENT PLASTER (TWO COAT WORK)
13.3.1 The specification for scaffolding and preparation of surface shall be as described in 13.1
13.3.2 Mortar
The mix and type of fine aggregate specified in the description of the item shall be used for the
respective coats. Generally the mix of the finishing coat shall not be richer than the under coat
unless otherwise described in item.
Generally coarse sand shall be used for the under coat and fine sand for the finishing coat,
unless otherwise specified for external work and under coat work, the fine aggregate shall conform
to grading zone IV. For finishing coat work the fine aggregate conforming to grading zone V shall be
used.
13.3.3 Application
13.3.3.1 The plaster shall be applied in two coats i.e. 12 mm under coat and then 6 mm finishing
coat and shall have an average total thickness of not less than 18 mm.
13.3.3.2 12 mm Under Coat : This shall be applied as specified in 13.1.4 except that when the
plaster has been brought to a true surface a wooden straight edge and the surface shall be left
rough and furrowed 2 mm deep with a scratching tool diagonally both ways, to form key for the
finishing coat. The surface shall be kept wet till the finishing coat is applied.
13.3.3.3 6 mm Finishing Coat : The finishing coat shall be applied after the under coat has sufficiently
set but not dried and in any case within 48 hours and finished in the manner specified in 13.1.4.
13.3.4 Specifications for Curing, Finishing, Precautions, Measurements and Rate shall be as described
under 13.1.
13.4 6 MM CEMENT PLASTER ON CEMENT CONCRETE AND REINFORCED CEMENT CONCRETE

WORK
13.4.1 Scaffolding
Stage scaffolding shall be provided for the work. This shall be independent of the walls.

Projecting burrs of mortar formed due to the gaps at joints in shuttering shall be removed. The
surface shall be scrubbed clean with wire brushes. In addition concrete surfaces to be plastered
shall be pock marked with a pointed tool, at spacings of not more than 5 cm. Centres, the pock being
made not less than 3 mm deep. This is to ensure a proper key for the plaster. The mortar shall be
washed off and surface, cleaned off all oil, grease etc. and well wetted before the plaster is applied.
13.4.3 Mortars
Mortar of the specified mix using the types of sand described in the item shall be used. It shall be
as specified in 3.2.
13.4.4 Application
To ensure even thickness and a true surface, gauges of plaster 15 x 15 cm. shall be first applied
at not more than 1.5 m intervals in both directions to serve as guides for the plastering. Surface of
these gauged areas shall be truly in the plane of the finished plaster surface. The plaster shall be
then applied in a uniform surface to a thickness slightly more than the specified thickness and shall
then be brought to true and even surface by working a wooden straight edge reaching across the
gauges. Finally the surface shall be finished true with a trowel or with wooden float to give a smooth
or sandy granular texture as required. Excess troweling or over working of the floats shall be avoided.
The plastering and finishing shall be completed within half an hour of adding water to the dry mortar.
Plastering of ceiling shall not be commenced until the slab above has been finished and centring
has been removed. In the case of ceiling of roof slabs, plaster shall not be commenced until the
terrace work has been completed. These precautions are necessary in order that the ceiling plaster
is not disturbed by the vibrations set up in the above operations.
13.4.5 Finish
The plaster shall be finished to a true and plumb surface and to the proper degree of smoothness
as required. The work shall be tested frequently as the work proceeds with a true straight edge not
less than 2.5 m long and with plumb bobs. All horizontal lines and surfaces shall be tested with a level
and all jambs and corners with a plumb bob as the work proceeds.
13.4.6 Thickness
The average thickness of plaster shall not be less than 6 mm. The minimum thickness over any
portion of the surface shall not be less than 5 mm.
13.4.7 Curing
The specifications shall be as detailed in 13.1.6.
13.4.8 Precautions
The specifications shall be as detailed in 13.1.8.
13.4.9 Measurements
13.4.9.1 Length and breadth shall be measured correct a cm. and its area shall be calculated in
sqm. correct to two places of decimal. Dimensions before plastering shall be taken.
13.4.9.2 Thickness of plaster shall be exclusive of the thickness of the key i.e. depth or rock marks
and hacking.
13.4.9.3 Plastering on ceiling at height greater than 5 m above the corresponding floor level shall be
so described and shall be measured separately stating the height in stages of 1 m or part thereof.

13.4.9.4 Plastering on the sides and soffits of the projected beams of ceiling at a height greater than
5 m above the corresponding floor level shall be measured and added to the quantity measured
under 13.4.9.3.
13.4.9.5 Plastering on spherical and groined ceiling and circular work not exceeding 6 m in radius,
shall be measured and paid for separately.
13.4.9.6 Flowing soffits (viz. portion under spiral stair case etc.) shall be measured and paid for
separately.
13.4.9.7 Ribs and mouldings on ceiling shall be measured as for cornices, deductions being made
from the plastering on ceiling in case the width of the moulding exceed 15 cm.
13.4.9.8 The mode of measurement of exterior plastering and patch plastering (in repairs) shall be
as laid down in 13.1.9.8
13.4.9.9 Deduction shall not be made for openings or for ends of columns, or columns caps of 0.5
sqm each in area and under. No additions will be made either for the plastering of the sides of such
openings. For openings etc. of areas exceeding 0.5 sqm deduction will be made for the full opening
but the sides of such openings shall be measured for payment.
13.4.10 Rate
above.
13.5 6 MM CEMENT PLASTER FOR SLAB BEARING
13.5.0 Cement plaster shall be 6 mm thick finished with a floating coat of neat cement and thick coat
of lime wash on top of walls for bearing of slabs.
13.5.1 Application
The plaster shall be applied over the cleaned and wetted surface of the wall. When the plaster has
been brought to a true surface with the wooden straight edge (Clause 13.1.4) it shall be uniformly
treated over its entire area with a paste of neat cement and rubbed smooth, so that the whole surface
is covered with neat cement coating. The quantity of cement applied for floating coat shall be 1 kg per
sqm. Smooth finishing shall be completed with trowel immediately and in no case later than half an hour
of adding water to the plaster mix. The rest of the specifications described in 13.1.4 shall apply.
13.5.2 Lime wash

This shall be applied in a thick coat after curing the plaster for three days.
13.5.3 Measurements
Length and breadth shall be measured correct to a cm and area worked out in sqm correct to two
places of decimal.
13.5.4 Rate
The rate shall include the cost of all labour and materials involved in all the operations
described above.
13.6 NEAT CEMENT PUNNING
13.6.1 The specifications given for floating coat described in 13.2.1 shall apply.
13.6.2 Specification for scaffolding and curing shall be as described in 13.1.1 and 13.1.6. respectively.
Specifications for Finish and Precautions shall be as described in 13.1.7. and 13.1.8.

13.6.3 Measurements
13.6.3.1 The measurements for cement punning shall be taken over the finished work. The length
and breadth shall be measured correct to a cm. The area shall be calculated in sqm correct to two
places of decimal.
13.6.3.2 Punning over Plaster on bands, skirting, coping, cornices, drip courses, string courses etc.
shall not be measured separately but only as wall surfaces. In these cases the measurements shall
be taken girthed over the above features.
13.6.3.3 Punning over plaster on circular work also, of any radius shall be measured only as wall
surfaces, and not separately.
13.6.3.4 Cement punning in patch repairs irrespective of the size of the patch shall be measured as
new work, and in this case the rate shall include for cutting the patch to rectangular shape before
lime punning.
13.6.3.5 Deductions in measurements for openings shall be regulated generally as described in 13.1.9.9.
13.6.4 Rate
above.
13.7 ROUGH CAST PLASTER

13.7.0 Rough cast finish comprises of a mixture of sand and gravel in specified proportions dashed
over a freshly plastered surface.
13.7.1 Scaffolding
Scaffolding shall be done as specified in 13.1.1.

The joints shall be raked out, dust and loose mortar, shall be brushed out. The surface shall be
thoroughly washed with water, cleaned and kept wet before plastering is commenced.
13.7.3 Mortar
Mortar of specified mix using the type of sand described in the item shall be used, where coarse
sand is to be used, the fineness modulus of the sand shall not be less than 2.5 mm.
13.7.4 Application
13.7.4.1 The plaster base over which rough cast finish is to be applied shall consist of two coats,
under layer 12 mm thick and top layer 10 mm.
13.7.4.2 12 mm Under Layer : This shall be applied in the same manner as specified in para 13.1.3
under 18 mm cement plaster except that the finishing, after the mortar has been brought to a level
with the wooden straight edge, shall be done with wooden float only.
13.7.4.3 Top Layer : The top layer shall be applied a day or two after the under layer has taken
initial set. The latter shall not be allowed to dry out, before the top layer is laid on. The mortar used
for applying top layer shall be sufficiently plastic and of rich mix 1 : 3 (1 cement : 3 fine sand) or as
otherwise specified so that the mix of sand and gravel gets well pitched with the plaster surface. In
order to make the base plastic, about 10% of finely grouted hydrated lime by volume of cement, shall
be added when preparing mortar for the top layer.

13.7.5 Finish
It shall be ensured that the base surface which is to receive rough cast mixture is in plastic state.
The rough cast mixture shall consist of sand or gravel or crushed stone of uniform colour from 2.36
mm to 12.5 mm or as specified and in the proportions as specified accurately to the effect required.
The mixture shall be wetted and shall be dashed on the plaster base in plastic state by hand scoop
so that the mix get well pitched into the plaster base. The mix shall again be dashed over the vacant
spaces if any so that the surface represents a homogeneous surfaces of sand mixed with gravel. A
sample of rough cast plaster shall be got approved by the Engineer-in-Charge.
13.7.6 Specification for other details like precautions, measurement and rate shall be as described
under 13.1.
13.8 PEBBLE DASH FINISH (IN SITU WORK)

13.8.1 The specification shall be the same as for rough cast plaster, except that the washed pebble
or crushed stone graded from 12.5 mm to 6.3 mm or as specified shall be dashed over the plaster
base and the vacant spaces if any shall be filled in by pressing pebbles or crushed stone as specified
by hand, so that the finished surface represents a homogeneous surface.
13.8.2 Specification for scaffolding, preparation of surface, Mortar, Measurements and Rate shall be
as described under 13.7.
13.9 PLAIN BANDS OF CEMENT MORTAR

13.9.0 ‘Plain band’ is a plaster strip of uniform width not exceeding 30 cm and of uniform thickness,
provided for decorative or other purpose flush with, sunk below or projecting beyond, the wall plaster.
A flush band is one where due to the difference in mix or shade of the mortar, the band is executed as
a separate and distinct operation from the wall plaster.
13.9.1 Thickness
The thickness of a raised band is the thickness of the projection beyond the plane of the wall
plaster.
In the case of a flush or a sunk band, the thickness will be the thickness of the plaster measured
from the untreated wall surface.
13.9.2 Preparation of Surfaces and Application

13.9.2.1 In the case of flush or sunk bands the joints shall be raked out properly. Dust and loose
mortar shall be brushed out. Efflorescence if any shall be removed by brushing the scraping. The
surface shall then be thoroughly washed with water, cleaned and kept wet before plastering is
commenced.
13.9.2.2 In case of raised band, the surface shall be prepared as specified in 13.1.4. The surface of
the wall plaster behind the band shall be left rough and furrowed 2 mm deep with a scratching tool,
diagonally both ways to form key for the band. No reduction in the rate for the above backing wall
plaster shall, however, be made for not finishing the same smooth.
13.9.3 Mortar
Mortar of the mix and type of sand specified in the description of the item shall be used.

13.9.4 Finish
The bands shall be finished exactly to the size as shown in the drawings. The horizontal or vertical lines
of bands shall be truly parallel and straight and the surfaces shall be finished truly plane and smooth. The
lines and surfaces shall be checked with fine threads for straightness, level and accuracy.
13.9.5 Scaffolding, Curing and Precaution shall be as described under 13.1.
13.9.6 Measurements
Length will be measured in running metres correct to a cm. The length shall be taken along the finished
face. The width shall not be measured by girth. For width of band 30 cm or below, the width shall be measured
in cm correct to 5 mm. The quantity shall be calculated in metre-cm units.
13.9.7 Rate
The rate shall include the cost of all labour and materials involved in all the operations described above.
Nothing extra shall be paid for mitres, stops nor for bands on curved surfaces of whatever radius, they may be.
The rate is also inclusive of all rounding or chamfering at corners, arrisers, providing grooves at junctions etc.
13.10 MOULDED BANDS OF CEMENT MORTAR (SINGLE COAT WORK)

13.10.0 Moulded band is a plaster strip of uniform width but with varying thickness across its section formed
over wall plaster for decorative purposes. The sectional periphery of the band is formed by a combination of
straight lines or of curves or of straight lines and curves.
13.10.1 Thickness
The higher thickness stipulated in the description of the item shall refer to the upper limiting thickness of
the moulding at its most projected portion, measured from the wall plaster.
13.10.2 Preparation of Surface, Mortar, Scaffolding, Curing and Precautions shall be as specified under 13.9.
13.10.3 Application and Finish

Proper templates conforming accurately to the sectional periphery of the moulded band shall be got
approved, before use. The finished band shall be true to the template at all sections. The lines of the band
shall be truly parallel and straight and surfaces smoothly finished.
13.10.4 Measurements
The width of the band 30 cm or below shall be measured in cm correct to 5 mm and shall be measured
along the sectional periphery of the moulded band, from wall plaster face to wall plaster face. The length shall
be measured, in running metres correct to a cm. It shall be taken along the finished face of the band at the
centre of its girth. The quantity should be calculated in metre-cm units.
13.10.5 Rate
Nothing extra shall be paid for mitres, stops nor for bands on curved surfaces of whatever radius, they may be.
The rate is also inclusive of all rounding or chamfering at corners, arrisers etc.
13.11 MOULDED BANDS OF CEMENT MORTAR (TWO COAT WORK)

13.11.0 Moulded band is a plaster strip of uniform width but with varying thickness across its section formed
over wall plaster for decorative purposes. The sectional periphery of the band is formed by a combination of
straight lines or of curves or of straight lines and curves.
13.11.1 Thickness
The higher thickness stipulated for the under coat in the description of the item shall refer to the upper
limiting thickness of the under coat of the moulding at its most projected portion from the wall plaster.
The thickness stipulated for the finishing coat is the uniform thickness of the finished peripheral surface of
the moulded band from the under coat.

13.11.2 Mortar
The under coat shall consist of cement mortar 1 : 5 (1 cement : 5 coarse sand) and the top coat shall be
of cement mortar 1 : 4 (1 cement : 4 fine sand) unless otherwise specified in the description of item.
13.11.3 Application and Finish

Proper templates conforming to the sectional periphery of the moulded band as at the stages of the under
coat and the finished final coat shall be made and got approved and used at the proper stages in executing
the bands to true and accurate profile. The lines of the bands as finally completed shall be truly parallel and
straight and the surfaces smoothly finished.
13.11.4 All other details shall be as specified under 13.10.
13.12 CEMENT WATER PROOFING COMPOUND

13.12.0 It shall be used for cement mortar for plastering or concrete work.
13.12.1 Water Proofing Compound

Integral cement water proofing compound conforming to IS 2645 and of approved brand and manufacture,
enlisted by the Engineer-in-Charge from time to time shall be used.
13.12.2 The contractor shall bring the materials to the site in their original packing. The containers will be
opened and the material mixed with dry cement in the proportion by weight, recommended by the manufacturers
or as specifically described in the description of the item. Care shall be taken in mixing, to see that the water
proofing material gets well and integrally mixed with the cement and does not run out separately when water
is added.
13.12.3 It shall be measured by weight.
13.12.4 The rate shall include the cost of all labour and materials involved in all the operations described
above.
13.13 POINTING ON BRICK WORK, TILE WORK AND STONE WORK

13.13.0 Pointing shall be of the type shown in figure below:
Drawings not to Scale

13.13.1 Scaffolding
For all exposed brick work, tile work or stone work independent double scaffolding having two
sets of vertical supports shall be provided. The supports shall be sound and strong tied together
with horizontal pieces over which scaffolding planks shall be fixed.
For all other work in building, single scaffolding shall be permitted. In such cases, the inner end
of the horizontal scaffolding pole shall rest in a hole provided only in the header course for the
purpose. Only one header for each pole shall be left out. Such holes for scaffolding shall, however,
not be allowed in pillars/columns less than one metre in width, or immediately near the skew backs of
arches. The holes left in masonry works for scaffolding purposes shall be filled and made good
before plastering.
Note : In case of special type of work, scaffolding shall be got approved from Engineer-in-Charge in
advance.
13.13.2 Preparation of surface

The joints shall be raked out properly. Dust and loose mortar shall be brushed out. Efflorescence
if any shall be removed by brushing and scraping. The surface shall then be thoroughly washed with
water, cleaned and kept wet before pointing is commenced.
The joints shall be raked to such a depth that the minimum depth of the new mortar measured
from either the sunk surface of the finished pointing or from the edge of the brick shall not be less
than 12 mm.
13.13.3 Mortar
Mortar of specified mix shall be used. It shall be as specified under Chapter 3.0.
13.13.4 Application and Finishing

13.13.4.1 The mortar shall be pressed into the raked out joints, with a pointing trowel, either flush,
sunk or raised, according to the type of pointing required. The mortar shall not spread over the
corner, edges or surface of the masonry. The pointing shall then be finished with the proper tool, in
the manner described below:
13.13.4.2 Flush Pointing : The mortar shall be pressed into the joints and shall be finished off flush
and level with the edges of the bricks, tiles or stones so as to give a smooth appearance. The edges
shall be neatly trimmed with a trowel and straight edge.
13.13.4.3 Ruled Pointing : The joints shall be initially formed as for flush pointing and then while the
mortar is still green, a groove of shape and size as shown in drawings or as instructed, shall be
formed by running a forming tool, straight along the centre line of the joints. This operation shall be
continued till a smooth and hard surface is obtained. The vertical joints shall also be finished in a
similar way. The vertical lines shall make true right angles at their junctions with the horizontal lines
and shall not project beyond the same.
13. 13.4.4 Cut or Weather Struck Pointing: The mortar shall first be pressed into the joints. The
top of the horizontal joints shall then be neatly pressed back about 3 mm or as directed, with the
pointing tool so that the joints are sloping from top to bottom.
The vertical joints shall be ruled pointed. The junctions of vertical joints with the horizontal joints
shall be at true right angles.

13.13.4.5 Raised and Cut Pointing : Raised and cut pointing shall project from the wall facing with its edges
cut parallel so as to have a uniformly raised band about 6 mm raised and width 10 mm more as directed.
13.13.4.6 The superfluous mortar shall then be cut off from the edges of the lines and the surface of the
masonry shall also be cleaned off all mortar. The finish shall be such that the pointing is to the exact size and
shape required and the edges are straight, neat and clean.
13.13.5 Curing
The pointing shall be kept wet for seven days. During this period it shall be suitably protected from all damages.
The pointing lines shall be truly horizontal and vertical except where the joints are slanting as in rubble
random masonry. Lines of joints from different directions should meet neatly at the junctions instead of
crossing beyond.
13.13.6.1 Length and breadth shall be measured correct to a cm and its area shall be calculated in square
metres upto two places of decimal.
13.13.6.2 The various types of pointing for example, struck, keyed, flush, tuck, etc. shall each be measured
separately.
13.13.6.3 Pointing on different types of walls, floors, roofs etc. shall each be measured separately. The type
and material of the surface to be pointed shall be described.
13.13.6.4 Pointing in a single detached joint as for flashing shall be given in running metres.
13.13.6.5 For jambs, soffits, sills etc. for opening not exceeding 0.5 sqm each in area, ends of joists, beams,
posts, girders, steps etc. not exceeding 0.5 sqm each in area and opening not exceeding 3 sqm each
deductions and additions shall be made in the following way, in case of pointing on external face only.
(a) No deduction shall be made for ends of joists, beams, posts etc. and openings not exceeding 0.5
sqm each, and no addition shall be made for reveals, jambs, soffits, sills, etc. of these openings.
(b) Deductions for openings exceeding 0.5 sqm but not exceeding 3 sqm each shall be made as follows
and no additions shall be made for reveals, jambs, soffits, sills, etc. for these openings.
(c) When both the faces of the wall are pointed with the same pointing deduction shall be made for one
face only.
(d) When two faces of wall are pointed with different pointings or if one face is plastered and other is
pointed or plastered, deduction shall be made from the plaster or pointing on the side of frames for
doors, windows, etc. on which the width of the reveal is less than that on the other side, but no
deduction shall be made from the other side.
(e) Where width of reveals on both faces of wall are equal, deduction of 50% of area of opening on each
face shall be made from area of pointing or plaster as the case may be.
(f) For opening having door frame equal to or projecting beyond thickness of wall, full deduction for
opening shall be made from each pointed face of wall.
13.13.6.6 In case of openings of area above 3 sqm each, deduction shall be made for the openings, but jambs,
soffits and sills shall be measured.
13.13.6.7 The following shall be measured separately.

(a) Raking out joints for old work only shall be measured and given in square metres.
(b) Raking out joints of old work built in mud mortar, lime mortar and cement mortar shall each be
measured separately.
(c) Raking out joints of different types of old walls, floors etc. shall each be measured separately.
(d) Raking single detached joints as for flashing old work shall be given in running metres.

13.13.7 Rate
The rate shall include the cost of all materials and labour involved in all the operations described
above.
13.13A WHITE CEMENT BASED POLYMER MODIFIED MORTAR

13.13A.1 Materials
Polymer modified mortar is a two component polymer modified repair mortar composed of
powder component based on cement binder, properly graded aggregates and additives & second
component is liquid polymer of approved make it is to be mixed with water on site to produce a highly
consistent, high strength cement mortar. It is specially designed for repairs of RCC members like
beams & columns, slabs & walls because it provides high compressive strength, high resistance to
chlorides and carbon dioxide.
13.13A.2 Scaffolding
Scaffolding as required for the proper execution of the work shall be erected. If work can be
done safely with the ladder or jhoola these will be permitted in place of scaffolding.
13.13A.3 Areas of Application

Repair & Reinstatement of Spalled concrete in RCC members beams, columns etc.
13.13A.4 Method of Application

13.13A.4.1 Surface Preparation
• Expose fully any corroded steel in the repair area and remove all scale and corrosion deposits
mechanically or ideally by grit blasting.
• Clean the surface and remove loose concrete, any dust, oil paint, grease etc.
13.13A.4.2 Priming
• Apply zinc primer of approved make over the cleaned re-bars & allow to dry before repair.
• The substrate should be primed by applying one neat/clear of bonding agent of approved
make.
13.13A.4.3 Mixing
• For normal application use of potable water as per manufacturer’s specifications
• First add polymer into water and mix for 2 minutes.
• Then add powder slowly and mix till homogeneous mix is obtained. Mixing must be done with
a mixer.
13.13A.4.4 Application
• Apply the mix to the prepared substrate by hand when primer becomes tacky. Ensure that the
material has reached evenly behind bars.
• Mix can be applied in required thickness as per item in a single application.
• Mild cure the prepared surface with water for 3 days.
13.13A.5 Measurements
Length and breadth shall be measured correct to a cm. The area shall be calculated in
square metre correct to two places of decimal.
Pre- measurements of the patches to be plastered shall be recorded after the old plaster has
been cut and surface prepared.
13.13A.6 Rate
The rate includes the cost of all the materials and labour involved in all the operations described
above.

13.14 WHITE WASHING WITH LIME
13.14.1 Scaffolding
13.14.1.1 Wherever scaffolding is necessary, it shall be erected on double supports tied together by
horizontal pieces, over which scaffolding planks shall be fixed. No ballies, bamboos or planks shall
rest on or touch the surface which is being white washed.
13.14.1.2 For all exposed brick work or tile work, double scaffolding having two sets of vertical
supports shall be provided. The supports shall be sound and strong, tied together with horizontal
pieces over which scaffolding planks shall be fixed.
Note: In case of special type of brick work, scaffolding shall be got approved from Engineer-in-
Charge in advance.
13.14.1.3 Where ladders are used, pieces of old gunny bags shall be tied on their tops to avoid
damage or scratches to walls.
13.14.1.4 For white washing the ceiling, proper stage scaffolding shall be erected.

Before new work is white washed, the surface shall be thoroughly brushed free from mortar
droppings an foreign matter.
In case of old work, all loose particles and scales shall be scrapped off and holes in plaster as
well as patches of less than 50 cm area shall be filled up with mortar of the same mix. Where so
specifically ordered by the Engineer -in- Charge, the entire surface of old white wash shall be
thoroughly removed by scrapping and this shall be paid for separately. Where efflorescence is observed
the deposits may be brushed clean and washed. The surface shall then be allowed to dry for atleast
48 hours before white washing is done.
13.14.3 Preparation of Lime Wash

13.14.3.1 The lime wash shall be prepared from fresh stone white lime (Narnaul or Dehradun quality).
The lime shall be thoroughly slaked on the spot, mixed and stirred with sufficient water to make a thin
cream. This shall be allowed to stand for a period of 24 hours and then shall be screened through a
clean coarse cloth. 40 gm of gum dissolved in hot water, shall be added to each 10 cubic dicimetre of
the cream. The approximate quantity of water to be added in making the cream will be 5 litres of
water to one kg of lime.
13.14.3.2 Indigo (Neel) upto 3 gm per kg of lime dissolved in water, shall then be added and stirred
well. Water shall then be added at the rate of about 5 litres per kg. of lime to produce a milky solution.
13.14.4 Application
13.14.4.1 The white wash shall be applied with moonj brushes to the specified number of coats. The
operation for each coat shall consist of a stroke of the brush given from the top downwards, another
from the bottom upwards over the first stroke, and similarly one stroke horizontally from the right and
another from the left before it dries.
13.14.4.2 Each coat shall be allowed to dry before the next one is applied. Further each coat shall be
inspected and approved by the Engineer-in-Charge before the subsequent coat is applied. No portion
of the surface shall be left out initially to be patched up later on.

13.14.4.3 For new work, three or more coats shall be applied till the surface presents a smooth and uniform
finish through which the plaster does not show. The finished dry surface shall not show any signs of cracking
and peeling nor shall it come off readily on the hand when rubbed.
13.14.4.4 For old work, after the surface has been prepared as described in para 13.14.2 a coat of white wash
shall be applied over the patches and repairs. Then a single coat or two or more coats of white wash as
stipulated in the description of the item shall be applied over the entire surface. The white washed surface
should present a uniform finish through which the plaster patches do not appear. The washing on ceiling
should be done prior to that on walls.
Note : In case of Hessian ceiling, on no account, lime shall be used as it rots cloth and hessian.
13.14.5 Protective Measures

Doors, windows, floors, articles of furniture etc. and such other parts of the building not to be white
washed, shall be protected from being splashed upon. Splashings and droppings, if any shall be removed by
the contractor at his own cost and the surfaces cleaned. Damages if any to furniture or fittings and fixtures
shall be recoverable from the contractor.
13.14.6.1 Length and breadth shall be measured correct to a cm. and area shall be calculated in sqm correct
to two places of decimals.
13.14.6.2 Measurements for Jambs, Soffits and Fills etc. for openings shall be as described in 13.1.9.
13.14.6.3 Corrugated surfaces shall be measured flat as fixed and the area so measured shall be increased
by the following percentages to allow for the girthed area.
Corrugated non-asbestos cement sheet 20%

Semi corrugated non-asbestos cement sheet 10%
13.14.6.4 Cornices and other such wall or ceiling features, shall be measured along the girth and included in
the measurements.
13.14.6.5 The number of coats of each treatment shall be stated. The item shall include removing nails,
making good holes, cracks, patches etc. not exceeding 50 sq. cm. each with material similar in composition
to the surface to be prepared.
13.14.6.6 Work on old treated surfaces shall be measured separately and so described.
13.14.7 Rate
The rate shall include all material and labour involved in all the operations described above.
13.15 SATNA LIME WASHING

13.15.0 Satna lime wash shall be used as a base coat where so specified. The specifications for ‘white
washing with lime’ shall apply except that Satna or Katni quality lime shall be used in place of Narnaul or
Dehradun quality lime and the wash will be mixed to a thicker consistency. The other details and specifications
described in 13.14 will apply in toto.
13.16 WHITE WASHING WITH WHITING
13.16.1 Preparation of Mix

Whiting (ground white chalk) shall be dissolved in sufficient quantity of warm water and thoroughly
stirred to form a thin slurry which shall then be screened through a clean coarse cloth. Two kg of gum and
0.4 kg of copper sulphate dissolved separately in hot water shall be added for every cum of the slurry which
shall then be diluted with water to the consistency of milk so as to make a wash ready for use.
13.16.2 Other specifications described in 13.14 shall apply in this case also.

13.17 COLOUR WASHING
13.17.1 The mineral colours, not affected by lime, shall be added to white wash. Indigo (Neel) shall
however, not be added. No colour wash shall be done until a sample of the colour wash of the
required tint or shade has been got approved from the Engineer-in-Charge. The colour shall be of
even tint or shade over the whole surface. If it is blotchy or otherwise badly applied, it shall be redone
by the contractor.
For new work, the priming coat shall be of white wash with lime or with whiting as specified in the
description of the item. Two or more coats, shall then be applied on the entire surface till it represents
a smooth and uniform finish.
For old work, after the surface has been prepared as described in 13.14.2 a coat of colour wash
shall be applied over the patches and repairs. Then a single coat, or two or more coats of colour
wash, as stipulated in the description of the item shall be applied over the entire surface. The colour
washed surface shall present a uniform finish.
The finished dry surface shall not be powdery and shall not readily come off on the hand when
rubbed.
13.17.2 Other specifications as described under 13.14.
13.18 DRY DISTEMPERING

13.18.1 Materials
Dry distemper of required colour (IS 427) and of approved brand and manufacture shall be used.
The shade shall be got approved from the Engineer-in-Charge before application of the distemper.
The dry distemper colour as required shall be stirred slowly in clean water using 6 decilitres (0.6 litre)
of water per kg of distemper or as specified by the makers. Warm water shall preferably be used. It
shall be allowed to stand for at least 30 minutes (or if practicable over night) before use. The mixture
shall be well stirred before and during use to maintain an even consistency.
Distemper shall not be mixed in larger quantity than is actually required for one day’s work.

13.18.2.1 Before new work is distempered, the surface shall be thoroughly brushed free from mortar
droppings and other foreign matter and sand papered smooth.
13.18.2.2 New plastered surfaces shall be allowed to dry completely, before applying, distemper.
13.18.2.3 In the case of old work, all loose pieces and scales shall be removed by sand papering.
The surface shall be cleaned of all grease, dirt, etc.
13.18.2.4 Pitting in plaster shall be made good with plaster of paris mixed with the colour to be used.
The surface shall then be rubbed down again with a fine grade sand paper and made smooth. A coat
of the distemper shall be applied over the patches. The patched surface shall be allowed to dry
thoroughly before the regular coat of distemper is applied.
13.18.3 Priming Coat

A priming coat of whiting (see 13.16) shall be applied over the prepared surface in case of new
work, if so stipulated in the description of the item. No white washing coat shall be used as a priming
coat for distemper.
The treated surface be allowed to dry before distemper coat is given.

13.18.4 Application
13.18.4.1 In the case of new work, the treatment shall consist of a priming coat of whiting (As per
13.16) followed by the application of two or more coats of distemper till the surface shows an
even colour.
13.18.4.2 For old work, the surface prepared as described in para 13.14 shall be applied one or
more coats of distemper till the surface attains an even colour.
13.18.4.3 The application of each coat shall be as follows:

The entire surface shall be coated with the mixture uniformly, with proper distemper brushes
(ordinary white wash brushed shall not be allowed) in horizontal strokes followed immediately by
vertical ones which together shall constitute one coat.
13.18.4.4 The subsequent coats shall be applied only after the previous coat has dried.
13.18.4.5 The finished surface shall be even and uniform and shall show no brush marks.
13.18.4.6 Enough distemper shall be mixed to finish one room at a time. The application of a coat in
each room shall be finished in one operation and no work shall be started in any room, which cannot
be completed the same day.
13.18.4.7 After each day’s work, the brushes shall be washed in hot water and hung down to dry. Old
brushes which are dirty or caked with distemper shall not be used.
13.18.5 The specifications in respect of scaffolding, protective measures, measurements and rate
shall be as described under 13.14.
13.19 OIL EMULSION (OIL BOUND) WASHABLE DISTEMPERING

13.19.1 Materials
Oil emulsion (Oil Bound) washable distemper (IS 428) of approved brand and manufacture shall
be used. The primer where used as on new work shall be cement primer or distemper primer as
described in the item. These shall be of the same manufacture as distemper. The distemper shall be
diluted with water or any other prescribed thinner in a manner recommended by the manufacturer.
Only sufficient quantity of distemper required for day’s work shall be prepared.
The distemper and primer shall be brought by the contractor in sealed tins in sufficient quantities
at a time to suffice for a fortnight’s work, and the same shall be kept in the joint custody of the
contractor and the Engineer-in-Charge. The empty tins shall not be removed from the site of work,
till this item of work has been completed and passed by the Engineer-in-Charge.
13.19.2 Preparation of the Surface

13.19.2.1 For new work the surface shall be thoroughly cleaned of dust, old white or colour wash by
washing and scrubbing. The surface shall then be allowed to dry for at least 48 hours. It shall then be
sand papered to give a smooth and even surface. Any unevenness shall be made good by applying
putty, made of plaster of paris mixed with water on the entire surface including filling up the undulations
and then sand papering the same after it is dry.
13.19.2.2 In the case of old work, all loose pieces and scales shall be removed by sand papering.
The surface shall be cleaned of all grease, dirt etc.
Pitting in plaster shall be made good with plaster of paris mixed with the colour to be used. The
surface shall then be rubbed down again with a fine grade sand paper and made smooth. A coat of
the distemper shall be applied over the patches. The patched surface shall be allowed to dry thoroughly
before the regular coat of distemper is applied.

13.19.3 Application
13.19.3.1 Priming Coat : The priming coat shall be with distemper primer or cement primer, as
required in the description of the item. The application of the distemper primer shall be as described
in 13.18.4.
Note : If the wall surface plaster has not dried completely, cement primer shall be applied before
distempering the walls. But if distempering is done after the wall surface is dried completely,
distemper primer shall be applied.
Oil bound distemper is not recommended to be applied, within six months of the completion of
wall plaster. However, newly plastered surfaces if required to be distempered before a period of six
months shall be given a coat of alkali resistant priming Paint conforming to IS 109 and allowed to dry
for atleast 48 hours before distempering is commenced.
For old work no primer coat is necessary.
13.19.3.2 Distemper Coat : For new work, after the primer coat has dried for at least 48 hours, the
surface shall be lightly sand papered to make it smooth for receiving the distemper, taking care not
to rub out the priming coat. All loose particles shall be dusted off after rubbing. One coat of distemper
properly diluted with thinner (water or other liquid as stipulated by the manufacturer) shall be applied
with brushes in horizontal strokes followed immediately by vertical ones which together constitutes
one coat.
The subsequent coats shall be applied in the same way. Two or more coats of distemper as are
found necessary shall be applied over the primer coat to obtain an even shade.
A time interval of at least 24 hours shall be allowed between successive coats to permit proper
drying of the preceding coat.
For old work the distemper shall be applied over the prepared surface in the same manner as in
new work. One or more coats of distemper as are found necessary shall be applied to obtain an even
and uniform shade.
15 cm double bristled distemper brushes shall be used. After each days work, brushes shall be
tho-roughly washed in hot water with soap solution and hung down to dry. Old brushes which are
dirty and caked with distemper shall not be used on the work.
13.19.4 The specifications in respect of scaffolding, protective measures and measurements shall
be as described under 13.14.
13.19.5 Rate
The rate shall include the cost of all labour and materials involved in all the above operations
(including priming coat) described above.
13.19A 1st QUALITY ACRYLIC DISTEMPER

13.19A.1 Materials
1st quality acrylic distemper having VOC content less than 50 gms/litre of approved brand and
manufacture shall be used. The acrylic distemper shall be diluted with water or any other prescribed
thinner in a manner recommended by the manufacturer. Only sufficient quantity of distemper required
for day’s work shall be prepared.

The distemper shall be brought by the contractor in sealed tins in sufficient quantities at a time to
suffice for a fortnight’s work, and the same shall be kept in the joint custody of the contractor and the
Engineer-in-Charge. The empty tins shall not be removed from the site of work, till this item of work
has been completed and passed by the Engineer-in-Charge.
13.19A.2 Preparation of the Surface

13.19A.2.1 For new work the surface shall be thoroughly cleaned of dust, old white or colour wash by
washing and scrubbing. The surface shall then be allowed to dry for at least 48 hours. It shall then be
sand papered to give a smooth and even surface. Any unevenness shall be made good by applying
putty, made of plaster of paris mixed with water on the entire surface including filling up the undulations
and then sand papering the same after it is dry.
13.19A.2.2 In the case of old work, all loose pieces and scales shall be removed by sand papering.
The surface shall be cleaned of all grease, dirt etc.
Pitting in plaster shall be made good with plaster of paris mixed with the colour to be used. The
surface shall then be rubbed down again with a fine grade sand paper and made smooth. A coat of
the distemper shall be applied over the patches. The patched surface shall be allowed to dry thoroughly
before the regular coat of distemper is applied.
13.19A.3 Application
13.19A.3.1 Priming Coat : The priming coat shall be with distemper primer or cement primer, as
required in the description of the item. The application of the distemper primer shall be as described
in 13.18.4.
Note : If the wall surface plaster has not dried completely, cement primer shall be applied before
distempering the walls. But if distempering is done after the wall surface is dried completely,
distemper primer shall be applied.
For old work no primer coat is necessary.
13.19A.3.2 Distemper Coat : For new work, after the primer coat has dried for at least 48 hours, the
surface shall be lightly sand papered to make it smooth for receiving the distemper, taking care not
to rub out the priming coat. All loose particles shall be dusted off after rubbing. One coat of distemper
properly diluted with thinner (water or other liquid as stipulated by the manufacturer) shall be applied
with brushes in horizontal strokes followed immediately by vertical ones which together constitutes
one coat.
The subsequent coats shall be applied in the same way. Two or more coats of distemper as are
found necessary shall be applied over the primer coat to obtain an even shade.
A time interval of at least 24 hours shall be allowed between successive coats to permit proper
drying of the preceding coat.
For old work the distemper shall be applied over the prepared surface in the same manner as in
new work. One or more coats of distemper as are found necessary shall be applied to obtain an even
and uniform shade.
15 cm double bristled distemper brushes shall be used. After each days work, brushes shall be
tho-roughly washed in hot water with soap solution and hung down to dry. Old brushes which are
dirty and caked with distemper shall not be used on the work.

13.19A.4 The specifications in respect of scaffolding, protective measures and measurements shall
be as described under 13.14.
13.19A.5 Rate
The rate shall include the cost of all labour and materials involved in all the above operations
(including priming coat) described above.
13.20 CEMENT PRIMER COAT

13.20.0 Cement primer coat is used as a base coat on wall finish of cement, lime or lime cement
plaster or on non-asbestos cement surfaces before oil emulsion distemper Paints are applied on
them. The cement primer is composed of a medium and pigment which are resistant to the alkalies
present in the cement, lime or lime cement in wall finish and provides a barrier for the protection of
subsequent coats of oil emulsion distemper Paints.
Primer coat shall be preferably applied by brushing and not by spraying. Hurried priming shall be
avoided particularly on absorbent surfaces. New plaster patches in old work should also be treated
with cement primer before applying oil emulsion Paints etc.
13.20.1 Preparation of the Surface

The surface shall be thoroughly cleaned of dust, old white or colour wash by washing and scrubbing.
The surface shall then be allowed to dry for at least 48 hours. It shall then be sand papered to give
a smooth and even surface. Any uneveness shall be made good by applying putty, made of plaster
of paris mixed with water on the entire surface including filling up the undulations and then sand
papering the same after it is dry.
13.20.2 Application
The cement primer shall be applied with a brush on the clean dry and smooth surface. Horizontal
strokes shall be given first and vertical strokes shall be applied immediately afterwards. This entire
operation will constitute one coat. The surface shall be finished as uniformly as possible leaving no
brush marks. It shall be allowed to dry for at least 48 hours, before oil emulsion Paint is applied.
13.20.3 The Specifications in respect of scaffolding, protective measures, measurements and rate
shall be as described under 13.1.4.
13.21 CEMENT PAINT

13.21.1 Material
The cement Paint shall be (conforming to IS 5410) of approved brand and manufacture.
The cement Paint shall be brought to the site of work by the contractor in its original containers is
sealed condition. The material shall be brought in at a time in adequate quantities to suffice for the
whole work or at least a fortnight’s work. The materials shall be kept in the joint custody of the
Contractor and the Engineer-in- Charge. The empty containers shall not be removed from the site of
work till the relevant item of the work has been completed and permission obtained from the Engineer-
in-Charge.

For New Work, the surface shall be thoroughly cleaned of all mortar dropping, dirt dust, algae,
grease and other foreign matter by brushing and washing. Pitting in plaster shall be made good and
a coat of water proof cement Paint shall be applied over patches after wetting them thoroughly.

13.21.3 Preparation of Mix
Cement Paint shall be mixed in such quantities as can be used up within an hour of its mixing as
otherwise the mixture will set and thicken, affecting flow and finish. Cement Paint shall be mixed with
water in two stages. The first stage shall comprise of 2 parts of cement Paint and one part of water
stirred thoroughly and allowed to stand for 5 minutes. Care shall be taken to add the cement Paint
gradually to the water and not vice versa. The second stage shall comprise of adding further one
part of water to the mix and stirring thoroughly to obtain a liquid of workable and uniform consistency.
In all cases the manufacturer’s instructions shall be followed meticulously.
The lids of cement Paint drums shall be kept tightly closed when not in use, as by exposure to
atmosphere the cement Paint rapidly becomes air set due to its hygroscopic qualities.
In case of cement Paint brought in gunny bags, once the bag is opened, the contents should be
consumed in full on the day of its opening. If the same is not likely to be consumed in full, the balance
quantity should be transferred and preserved in an airtight container to avoid its exposure to
atmosphere.
13.21.4 Application
13.21.4.1 The solution shall be applied on the clean and wetted surface with brushes or spraying
machine. The solution shall be kept well stirred during the period of application. It shall be applied on
the surface which is on the shady side of the building so that the direct heat of the sun on the surface
is avoided. The method of application of cement Paint shall be as per manufacturer’s specification.
The completed surface shall be watered after the day’s work.
13.21.4.2 The second coat shall be applied after the first coat has been set for at least 24 hours.
Before application of the second or subsequent coats, the surface of the previous coat shall not be
wetted.
13.21.4.3 For new work, the surface shall be treated with three or more coats of water proof cement
Paint as found necessary to get a uniform shade.
13.21.4.4 For old work, the treatment shall be with one or more coats as found necessary to get a
uniform shade.
13.21.5 Precaution
Water proof cement Paint shall not be applied on surfaces already treated with white wash,
colour wash, distemper dry or oil bound, varnishes, Paints etc. It shall not be applied on gypsums,
wood and metal surfaces.
If water proofing cement is required to be applied on existing surface, previously treated with
white wash, colour wash etc., the surface shall be thoroughly cleaned by scrapping off all the white
wash, colour wash etc. completely. Thereafter, a coat of cement primer shall be applied followed by
two or more coat of water proof cement.
shall be as described under 13.14. The coefficient for cement Paint on RCC Jalli shall be the same
as provided in Sl. No. 7 of Table 1 under para 13.23.6.4 for painting trellis for Jaffri work.
13.22 EXTERIOR PAINTING ON WALL

13.22.1 Material
The paint shall be (Texured exterior paint/Acrylic smooth exterior paint/premium acrylic smooth
exterior paint/100% premium acrylic emulsion paint) of approved brand and manufacture.

This paint shall be brought to the site of work by the contractor in its original containers in sealed
condition. The material shall be brought in at a time in adequate quantities to suffice for the whole
work or at least a fornight’s work. The materials shall be kept in the joint custody of the contractor
and the Engineer-in- Charge. The empty containers shall not be removed from the site of work till the
relevant item of work has been completed and permission obtained from the Engineer-in-Charge.

For new work, the surface shall be thoroughly cleaned off all mortar dropping, dirt dust, algae,
fungus or moth, grease and other foreign matter of brushing and washing, pitting in plaster shall
make good, surface imperfections such as cracks, holes etc. should be repaired using white cement.
The prepared surface shall have received the approval of the Engineer in charge after inspection
before painting is commenced.
13.22.3 Application
Base coat of water proofing cement paint
13.22.3.1 All specifications in respect of base coat of water proofing cement paint shall be as described
under 13.21.
13.22.3.2 Before pouring into smaller containers for use, the paint shall be stirred thoroughly in its
container, when applying also the paint shall be continuously stirred in the smaller containers so that its
consistency is kept uniform. Dilution ratio of paint with potable water can be altered taking into consideration
the nature of surface climate and as per recommended dilution given by manufacturer. In all cases, the
manufacturer’s instructions & directions of the Engineer-in-charge shall be followed meticulously.
The lids of paint drums shall be kept tightly closed when not in use as by exposure to atmosphere
the paint may thicken and also be kept safe from dust.
13.22.3.3 Paint shall be applied with a brush on the cleaned and smooth surface. Horizontal strokes
shall be given, First and vertical strokes shall be applied immediately afterwards. This entire operation
will constitute one coat. The surface shall be finished as uniformly as possible leaving no brush marks.
shall be as described under 13.14.
13.22A DELUXE MULTI SURFACE PAINT FOR INTERIORS AND EXTERIORS

13.22A.1 Material
The paint shall be (Deluxe multi surface paint for interiors and exteriors) of approved brand and
manufacture.
This paint shall be brought to the site of work by the contractor in its original containers in sealed
condition. The material shall be brought in at a time in adequate quantities to suffice for the whole
work or at least a fornight’s work. The materials shall be kept in the joint custody of the contractor
and the Engineer-in- Charge. The empty containers shall not be removed from the site of work till the
relevant item of work has been completed and permission obtained from the Engineer-in-Charge.
13.22A.2 Preparation of Surface

For new work, the surface shall be thoroughly cleaned off all mortar dropping, dirt dust, algae,
fungus or moth, grease and other foreign matter of brushing and washing, pitting in plaster shall
make good, surface imperfections such as cracks, holes etc. should be repaired using white cement.
The prepared surface shall have received the approval of the Engineer in charge after inspection
before painting is commenced.

13.22A.3 Application
Base coat of special primer of same manufacturer shall be used.
13.22A.3.1 All specifications in respect of base coat of water proofing cement paint shall be as described
under 13.21.
13.22A.3.2 Before pouring into smaller containers for use, the paint shall be stirred thoroughly in its container,
when applying also the paint shall be continuously stirred in the smaller containers so that its consistency is
kept uniform. Dilution ratio of paint with potable water can be altered taking into consideration the nature of
surface climate and as per recommended dilution given by manufacturer. In all cases, the manufacturer’s
instructions & directions of the Engineer-in-charge shall be followed meticulously.
The lids of paint drums shall be kept tightly closed when not in use as by exposure to atmosphere the
paint may thicken and also be kept safe from dust.
13.22A.3.3 Paint shall be applied with a brush on the cleaned and smooth surface. Horizontal strokes shall be
given, First and vertical strokes shall be applied immediately afterwards. This entire operation will constitute
one coat. The surface shall be finished as uniformly as possible leaving no brush marks.
13.22A.4 The specifications in respect of scaffolding, protective measures, measurements and rate shall be
as described under 13.14.
13.23 PAINTING
13.23.1 Materials
Paints, oils, varnishes etc. of approved brand and manufacture shall be used. Only ready mixed Paint
(Exterior grade) as received from the manufacturer without any admixture shall be used.
If for any reason, thinning is necessary in case of ready mixed Paint, the brand of thinner recommended
by the manufacturer or as instructed by the Engineer-in-Charge shall be used.
Approved Paints, oil or varnishes shall be brought to the site of work by the contractor in their original
containers in sealed condition. The material shall be brought in at a time in adequate quantities to suffice for
the whole work or at least a fortnight’s work. The materials shall be kept in the joint custody of the contractor
and the Engineer-in -Charge. The empties shall not be removed from the site of work, till the relevant item of
work has been completed and permission obtained from the Engineer-in-Charge.
13.23.2 Commencing Work

Painting shall not be started until the Engineer -in-Charge has inspected the items of work to be painted,
satisfied himself about their proper quality and given his approval to commence the painting work. Painting of
external surface should not be done in adverse weather condition like hail storm and dust storm.
Painting, except the priming coat, shall generally be taken in hand after practically finishing all other
building work.
The rooms should be thoroughly swept out and the entire building cleaned up, at least one day in advance
of the Paint work being started.

The surface shall be thoroughly cleaned and dusted off. All rust, dirt, scales, smoke splashes, mortar
droppings and grease shall be thoroughly removed before painting is started. The prepared surface shall have
received the approval of the Engineer-in-Charge after inspection, before painting is commenced.
13.23.4 Application
13.23.4.1 Before pouring into smaller containers for use, the Paint shall be stirred thoroughly in its containers,
when applying also, the Paint shall be continuously stirred in the smaller containers so that its consistency
is kept uniform.

13.23.4.2 The painting shall be laid on evenly and smoothly by means of crossing and laying off, the latter in the
direction of the grains of wood. The crossing and laying off consists of covering the area over with Paint, brushing
the surface hard for the first time over and then brushing alternately in opposite direction, two or three times and
then finally brushing lightly in a direction at right angles to the same. In this process, no brush marks shall be left
after the laying off is finished. The full process of crossing and laying off will constitute one coat.
13.23.4.3 Where so stipulated, the painting shall be done by spraying. Spray machine used may be (a) high
pressure (small air aperture) type, or (b) a low pressure (large air gap) type, depending on the nature and location
of work to be carried out. Skilled and experienced workmen shall be employed for this class of work. Paints used
shall be brought to the requisite consistency by adding a suitable thinner.
13.23.4.4 Spraying should be done only when dry condition prevails. Each coat shall be allowed to dry out
thoroughly and rubbed smooth before the next coat is applied. This should be facilitated by thorough ventilation.
Each coat except the last coat, shall be lightly rubbed down with sand paper or fine pumice stone and cleaned
off dust before the next coat is laid.
13.23.4.5 No left over Paint shall be put back into the stock tins. When not in use, the containers shall be kept
properly closed.
13.23.4.6 No hair marks from the brush or clogging of Paint puddles in the corners of panels, angles of
mouldings etc. shall be left on the work.
13.23.4.7 In painting doors and windows, the putty round the glass panes must also be painted but care must
be taken to see that no Paint stains etc. are left on the glass. Tops of shutters and surfaces in similar hidden
locations shall not be left out in painting. However, bottom edge of the shutters where the painting is not
practically possible, need not be done nor any deduction on this account will be done but two coats of primer
of approved make shall be done on the bottom edge before fixing the shutters.
13.23.4.8 On painting steel work, special care shall be taken while painting over bolts, nuts, rivets overlaps etc.
13.23.4.9 The additional specifications for primer and other coats of Paints shall be as according to the
detailed specifications under the respective headings.
13.23.5 Brushes and Containers

After work, the brushes shall be completely cleaned of Paint and linseed oil by rinsing with turpentine. A
brush in which Paint has dried up is ruined and shall on no account be used for painting work. The containers
when not in use, shall be kept closed and free from air so that Paint does not thicken and also shall be kept safe
from dust. When the Paint has been used, the containers shall be washed with turpentine and wiped dry with
soft clean cloth, so that they are clean, and can be used again.
13.23.6.1 The length and breadth shall be measured correct to a cm. The area shall be calculated in sqm
(correct to two places of decimal), except otherwise stated.
13.23.6.2 Small articles not exceeding 10 sq. decimetre (0.1 sqm) of painted surfaces where not in conjunction
with similar painted work shall be enumerated.
13.23.6.3 Painting upto 10 cm in width or in girth and not in conjunction with similar painted work shall be
given in running metres and shall include cutting to line where so required.
Note : Components of trusses, compound girders, stanchions, lattices and similar work shall, however, be
given in sq. metres irrespective of the size or girth of members. Priming coat of painting shall be included in
the work of fabrication.
13.23.6.4 In measuring painting, varnishing, oiling etc. of joinery and steel work etc. The coefficients as
indicated in following tables shall be used to obtain the area payable. The coefficients shall be applied to the
areas measured flat and not girthed.

TABLE 13.1
Equivalent Plain Areas of Uneven Surface
S.No Description of work How measured Multiplying coefficient

1 2 3 4
I. Wood work doors, windows Etc.
1. Panelled or framed and Measured flat (not girthed 1.30 (for each side)
braced doors, windows etc. including)
2. Ledged and battened or Chowkhat or frame, Edges, -do-
ledged, battened and braced chocks, cleats, etc. shall be
doors, windows etc. deemed to be included in the
item.
3. Flush doors etc. -do- 1.20 (for each side)
4. Part panelled and part glazed -do- 1.00 (for each side)
or gauzed doors, window etc.
(Excluding painting of wire
gauze portion)
5. Fully glazed or gauzed doors, -do- 0.80 (for each side)
windows etc. (Excluding
painting of wire gauze portion)
6. Fully venetioned or louvered -do- 1.80 (for each side)

doors, windows etc.
7. Trellis (or Jaffri) work one Measured flat overall, no 2 (for painting all over)
way or two way deduction shall be made for
open spaces, supporting
members shall not be
measured separately
8. Carved or enriched work Measured flat
9. Weather boarding Measured flat (not girthed 1.20 (for each side)
supporting frame work shall
not be measured separately
10. Wood shingle roofing Measured flat (not girthed) 1.10 (for each side)
11. Boarding with cover fillets and 1.05 (for each side)
match boarding
Measured flat (not girthed)
12. Tile and slate battening Measured flat overall no 0.80 (for painting all
deductions shall be made for over)
open spaces
II. Steel work doors, windows Etc.
13. Plain sheeted steel doors 1.10 (for each side)
or windows Measured flat (not girthed)
including frame edges etc.
14. Fully glazed or gauzed 0.50 (for each side)
steel doors and windows
(excluding painting of wire
gauze portion)
-do-
15. Partly panelled and partly -do- 0.80 (for each side)
glazed or gauzed doors
and windows (excluding
painting of wire gauze
portion)
16. Corrugated sheeted steel -do- 1.25 (for each side)

doors or windows

17. Collapsible gates Measured flat 1.50 (for painting all
over)
18. Rolling shutters of Measured flat (size of 1.10 (for each side)
interlocked laths opening) all over; jamb
guides, bottom rails and
locking arrangement etc. shall
be included in the item (top
cover shall be measured
separately)
III. General
19. Expanded metal, hard drawn Measured flat overall; no 1 (for Paint all over)
steel wire fabric of approved deduction shall be made
quality, grill works and for open spaces;
gratings in guard bars, supporting members shall
balustrades, railing partitions not be measured
and MS Bars in windows separately
frames.
20. Open palisade fencing and -do- 1 (for Paint all over)
gates including standards, (See note No.12)
braces, rails stays etc. in
timber or steel
21. Corrugated iron sheeting in -do- 1.14 (for each side)
roofs, side cladding etc. Measured flat (not
girthed)
22. AC corrugated sheeting in -do- 1.20 (for each side)
roofs, side cladding etc.
23. AC semi corrugated sheeting -do- 1.10 (for each side)

in roofs, side cladding etc. or
Nainital pattern using plain
sheets
24. Wire gauze shutters including -do- 1.00 (for each side)
painting of wire gauze
25. Hait Cut Bamboo fencing -do- 1.38 (AV) (for each
side)
Explanatory Notes for Table 13.1
(1) Measurements for doors windows etc., shall be taken flat (and not girthed) over all including
chowkhuts or frames, where provided. Where Chowkhuts or frames are not provided, the
shutter measurements shall be taken.
(2) Where doors, windows etc., are of composite types other than those included in Table 1 the
different portion shall be measured separately with their appropriate coefficients, the centre
line of the common rail being taken as the dividing line between the two portions.
(3) The coefficients for door and windows shall apply irrespective of the size of frames and shutter
members.
(4) In case steel frames are used the area of doors, windows shutters shall be measured flat
excluding frames.
(5) When the two faces of a door, window etc. are to be treated with different specified finishes,
measurable under separate items, the edges of frames and shutters shall be treated with the
one or the other type of finish as ordered by the Engineer-in-Charge and measurement of this
will be deemed to be included in the measurement of the face treated with that finish.
(6) In the case where shutters are fixed on both faces of the frames, the measurement for the
door frame and shutter on one face shall be taken in the manner already described, while the
additional shutter on the other face will be measured for the shutter only excluding the frame.

(7) Where shutters are provided with clearance at top or/and bottom each exceeding 15 cm height,
such openings shall be deducted from the overall measurements and relevant coefficient shall be
applied to obtain the area payable.
(8) Collapsible gates shall be measured for width from outside to outside of gate in its expanded position
and for height from bottom to top of channel verticals. No separate measurements shall be taken for
the top and bottom guide rails rollers, fittings etc.
(9) Coefficients for sliding doors shall be the same as for normal types of doors in the table. Measurements
shall be taken outside to outside of shutters, and no separate measurements shall be taken for the
painting guide rails, rollers, fittings etc.
(10) Measurements of painting as above shall be deemed to include painting all iron fittings in the same
or different shade for which no extra will be paid.
(11) The measurements of guard bars, expanded metal, hard drawn steel wire fabric of approved quality,
grill work and gratings, when fixed in frame work, painting of which is once measured else where
shall be taken exclusive of the frames. In other cases the measurements shall be taken inclusive of
the frames.
(12) For painting open palisade fencing and gates etc., the height shall be measured from the bottom of
the lowest rail, if the palisades do not go below it, (or from the lower end of the palisades, if they
project below the lowest rail), upto the top of rails or palisades whichever are higher, but not up to the
top of standards when the latter are higher than the top rails or the palisades.
13.23.6.5 Width of moulded work of all other kinds, as in hand rails, cornices, architraves shall be mea-sured
by girth.
13.23.6.6 For trusses, compound girders, stanchions, lattice girders, and similar work, actual areas will be
measured in sq. metre and no extra shall be paid for painting on bolt heads, nuts, washers etc. even when
they are picked out in a different tint to the adjacent work.
13.23.6.7 Painting of rain water, soil, waste, vent and water pipes etc. shall be measured in running metres of
the particular diameter of the pipe concerned. Painting of specials such as bends, heads, branches, junctions,
shoes, etc. shall be included in the length and no separate measurements shall be taken for these or for
painting brackets, clamps etc.
13.23.6.8 Measurements of wall surfaces and wood and other work not referred to already shall be recorded
as per actual.
13.23.6.9 Flag staffs, steel chimneys, aerial masts, spires and other such objects requiring special scaffolding
shall be measured separately.
13.23.7 Precautions
All furnitures, fixtures, glazing, floors etc. shall be protected by covering and stains, smears, splashings,
if any shall be removed and any damages done shall be made good by the contractor at his cost.
13.23.8 Rate
Rates shall include cost of all labour and materials involved in all the operations described above and in
the particular specifications given under the several items.
13.24 PAINTING PRIMING COAT ON WOOD, IRON OR PLASTERED SURFACES
13.24.1 Primer
13.24.1.1 The primer for wood work, iron work or plastered surface shall be as specified in the description of item.
13.24.1.2 Primer for plaster/wood work/Iron & Steel/Aluminium surfaces shall be as specified below:

TABLE 13.2
S.No Surfaces Primer to be used
1. Wood work (hard and soft wood) Pink conforming to IS 3536
2. Resinour wood and plywood Aluminium primer conforming to IS 3585
3. (A) Aluminium and light alloys Zinc chromate primer conforming to IS 104
(B) Iron, Steel and Galvanized steel Red Oxide Zinc chromate Primer
conforming IS 2074
4. Cement/Conc/RCC/brick work, Plastered Cement primer conforming to IS 109
surfaces, non-asbestos surfaces to receive
Oil bound distemper or Paint finish.
13.24.1.3 The primer shall be ready mixed primer of approved brand and manufacture.
13.24.1.4 Where primer for wood work is specified to be mixed at site, it shall be prepared from a
mixture of red lead, white lead and double boiled linseed oil in the ratio of 0.7 kg : 0.7 kg : 1 litre.
13.24.1.5 Where primer for steel work is specified to be mixed at site, it shall be prepared from a
mixture of red lead, raw linseed oil and turpentine in the ratio of 2.8 kg : 1 litre : 1 litre.
13.24.1.6 The specifications for the base vehicle and thinner for mixed on site primer shall be as
follows:
(a) White Lead : The White lead shall be pure and free from adulterants like barium sulphate
and whiting. It shall conform to IS 103.
(b) Red Lead : This shall be in powder form and shall be pure and free from adulterants like
brick dust etc. It shall conform to IS 102.
(c) Raw Linseed Oil : Raw linseed oil shall be lightly viscous but clear and of yellowish colour
with light brown tinge. Its specific gravity at a temperature of 30 degree C shall be between
0.923 and 0.928.
Note : The oil shall be mellow and sweet to the taste with very little smell. The oil shall be of
sufficiently matured quality. Oil turbid or thick, with acid and bitter taste and rancid odour and
which remains sticky for a considerable time shall be rejected. The oil shall conform in all
respects to IS 75. The oil shall be of approved brand and manufacture.
(d) Double Boiled Linseed Oil : This shall be more viscous than the raw oil, have a deeper
colour and specific gravity between 0.931 and 0.945 at a temperature of 30 degree C. It
shall dry with a glossy surface. It shall conform in all respects to IS 77. The oil shall be of
approved brand and manufacture.
Turpentine : Mineral turpentine i.e. petroleum distillate which has the same rate of evaporation as
vegetable turpentine (distillate product of oleeresin of conifers) shall be used. It shall have no grease
or other residue when allowed to evaporate. It shall conform to IS 533.
13.24.1.7 All the above materials shall be of approved manufacture and brought to site in their
original packing in sealed condition.

13.24.2.1 Wooden Surface : The wood work to be painted shall be dry and free from moisture.
The surface shall be thoroughly cleaned. All unevenness shall be rubbed down smooth with sand
paper and shall be well dusted. Knots, if any shall be covered with preparation of red lead made by
grinding red lead in water and mixing with strong glue sized and used hot. Appropriate filler material
conforming to IS 345 with same shade as Paint shall be used where specified. The surface treated

for knotting shall be dry before Paint is applied. After obtaining approval of Engineer-in-Charge for
wood work, the priming coat shall be applied before the wood work is fixed in position. After the
priming coat is applied, the holes and indentation on the surface shall be stopped with glazier’s putty
or wood putty. Stopping shall not be done before the priming coat is applied as the wood will absorb
the oil in stopping and the latter is therefore liable to crack.
13.24.2.2 Iron & Steel Surface : All rust and scales shall be removed by scrapping or by brushing
with steel wire brushes. Hard skin of oxide formed on the surface of wrought iron during rolling which
becomes loose by rusting, shall be removed.
All dust and dirt shall be thoroughly wiped away from the surface.
If the surface is wet, it shall be dried before priming coat is undertaken.
13.24.2.3 Plastered Surface : The surface shall ordinarily not be painted until it has dried completely.
Trial patches of primer shall be laid at intervals and where drying is satisfactory, painting shall then
be taken in hand. Before primer is applied, holes and undulations, shall be filled up with plaster of
paris and rubbed smooth.
13.24.3 Application
The primer shall be applied with brushes, worked well into the surface and spread even and smooth.
The painting shall be done by crossing and laying off as described in 13.22.3.3.
13.24.4 Treatment on Steel for Aggressive Environment

13.24.4.1 A second coat of ready mixed red oxide zinc chromate primer may be applied where consi-
dered necessary in aggressive environment such as near Industrial Establishment and Coastal regions
where the steel members are prone to corrosion. The second coat (which shall be paid for separately)
is to be applied after placing the member in position and just before applying Paint. The second coat
of primer is not necessary in case of painting with synthetic enamel Paint as it is applied over an
under coat of ordinary Paint.
13.24.4.2 The specifications described under 13.33 shall hold good so far as they are applicable.
13.24A EPOXY PAINT

13.24A.1 Material
This product has got excellent adhesion properties and offers a balanced aesthetic and
corrosion protective surface. Epoxy offers good resistance to water and humidity.
Epoxy coating are used because of their outstanding chemical resistance, durability, low porosity
and strong bond strength and it provides dry tough and protective coatings. Epoxy coatings are
created, by chemical reaction using an epoxide resin and polymine hardener.
13.24A.2 Painting new surface

13.24A.2.1 Surface must be dried, cleaned & made free from oil, grease, dirt, dust & all other
contaminants that could interfere with adhesion of coating.
The application of priming coat for relevant steel or cement surface shall be as per the
description of para no. 13.24. Epoxy paint is supplied in two parts i.e. (base and hardener). Stir the
base and hardener separately. Mix hardener gradually into the base under continuous stirring as per
mixing ratio as specified by the manufacturers.

The epoxy paint shall be consumed with in the working pot life as specified by the
manufacturers. Part mixing should be avoided.
To achieve optimum performance of the product, minimum 2-3 coats by brushing would be
required to get the desired dry film thickness (DFT) as specified by the manufacturer. Relative humidity
in the environment should preferably be below 85%.
13.24A.2.3 Cleaning
All equipments/apparatus shall be cleaned immediately after use with thinner especially the
hose pipes, gun, all spray equipments etc. All surplus material should be disposed off in compliance
with environmental pollution rules etc.
13.24A.2.4 General Safety

Contact of the product with skin specially with eyes should be avoided. Use of face mask is
mandatory during whole process. Proper ventilation is required and all safety procedures and
precautions are to be adopted for executing epoxy painting process.
13.24A.2.5 Measurement
Measurements, Rate and other details shall be as specified in Para 13.23 as far as they are
applicable which shall include the cost of all labour and material involved in all operation including
priming coat as described above.
13.25 PAINTING SYNTHETIC ENAMEL PAINT OVER G.S. SHEETS

13.25.0 Synthetic enamel
Paint, suitable for painting over G.S. sheets, of approved brand and manufacture and of the
required shade shall be used. New or weathered G.S. sheets shall be painted with a priming coat of
one coat of redoxide zinc chromate Paint. Primer shall be applied before fixing sheets in place.

13.25.1.1 Painting New Surface : The painting of new G.S. sheets shall not usually be done till the
sheets have weathered for about a year. When new sheets are to be painted before they have
weathered they shall be treated with a mordant solution prepared by mixing 38 gm of copper acetate
in a litre of soft water or 13 gm hydrochloric acid in a solution of 13 gm each of copper chloride,
copper nitrate and ammonium chloride dissolved in a litre of soft water. This quantity of solution is
sufficient for about 235 sqm. to 280 sqm of area and is applied for ensuring proper adhesion of
Paint. The painting with the mordant solution will be paid for separately.
Before painting on new or weathered G.S. sheets, rust patches shall be completely cleaned with
coarse emery paper and brush. All grease marks shall also be removed and the surface washed and
dried and rusted surface shall be touched with synthetic enamel paint of approved brand, manufacturer
and shade.
13.25.1.2 Painting Old Surface: If the old Paint is firm and sound, it shall be cleaned of grease,
smoke etc. The surface shall then be rubbed down with sand paper and dusted. Rusty patches shall
be cleaned up and touched with synthetic enamel paint.
If the old Paint is blistered and flaked, it shall be completely removed as described in 13.41. Such
removal shall be paid for separately and painting shall be treated as on new work.

13.25.2 Application
The number of coats to be applied shall be as in the description of item. In the case of C.G.S.
sheets, the crowns of the corrugations shall be painted first and when these get dried the general
coat shall be given to ensure uniform finish over the entire surface without the crowns showing signs
of thinning.
The second or additional coats shall be applied when the previous coat has dried.
13.25.3 The specifications described in 13.23 shall hold good so far as they are applicable.
13.26 PAINTING CAST IRON RAIN WATER, SOIL, WASTE AND VENT PIPES AND FITTINGS
13.26.1 The primer shall be prepared on site or shall be of approved brand and manufacture as
specified in the item.
Paint shall be anti-corrosive bitumastic Paint, aluminium Paint or other type of Paint as specified
in the description of the item.
13.26.2 Painting New Surface
13.26.2.1 Preparation of Surface : The surface shall be prepared for priming coat as described in
13.24.2.2.
13.26.2.2 Application : The number of coat of painting over the priming coat shall be as stipulated
in the description of the item. The application of Paint over priming coat shall be carried out as
specified in 13.25.
13.26.2.3 Measurements : Measurements will be taken over the finished line of pipe including specials
etc. in running metres, correct to a cm.
Pipes of different diameters of bore shall be measured and paid for separately.
Specials and fittings such as holder bat clamps, plugs etc. will not be measured separately.
13.26.2.4 Rate : The rate shall include the cost of all materials and labour involved in all the operations
described above, including painting of all specials and fittings.
13.26.2.5 Specifications described in 13.22 shall hold good as far as they are applicable.
13.26.3 Painting on Old Surface
13.26.3.1 The surface shall be prepared as specified in 13.25.1.2.
13.26.3.2 The specifications for application shall be as described in 13.22.3.
13.26.3.3 Measurements, rate and other details shall be as specified in 13.26.2.3.
13.27 PAINTING WITH WOOD PRESERVATIVE
13.27.1 Oil type wood preservative of specified quality and approved make, conforming to IS 218
shall be used. Generally, it shall be creosote oil type-I or anthracene oil.
13.27.2 Painting on New Surface

13.27.2.1 Preparation of Surface : Painting shall be done only when the surface is perfectly dry to
permit of good absorption. All dirt, dust or other foreign matter shall be removed from the surface to
be painted. All roughness shall be sand papered and cleaned.
13.27.2.2 Application : The preservative shall be applied liberally with a stout brush and not daubed
with rags or cotton waste. It shall be applied with a pencil brush at the joints of the wood work. The
first coat shall be allowed at least 24 hours to soak in before the second (the final) coat is applied.
The second coat shall be applied in the same manner as the first coat. The excess of preservative
which does not soak into the wood shall be wiped off with a clean dry piece of cloth.
13.27.2.3 The specifications described in 13.23 shall hold good in so far as they are applicable.

The work shall be done in the same manner as on new surface except that only one coat shall
be done.
13.27A FIRE RETARDANT PAINT

13.27A.1 Material
Ready to use, intumescent coating which effectively retards the flame spread and penetration
of heat through their intumescent subli mative-ablative and synergetic flame suppressing action. On
contact with flame, flame control intumescent fire retardant coating, decomposes and puff up (intumesce)
forming a thick, dense, spongy foam layer that retards heat penetration and flame spread.
13.27A.2 Polishing new surface

13.27A.2.1 Preparation of surface
Preparation of surface shall be as described in para 13.23.3. Surface must be dry, free from
dust, oil, wax, greases.
To achieve optimum performance of product apply fire retardant paint @ 2.86 litre/10 sqm
per coat or as specified by manufacturers in multiple coats with brush etc. using conventional French
polish process to achieve good result.
Measurements, Rate and other details shall be as specified in 13.23 as far as they are
applicable.
13.28 COAL TARRING

13.28.1 Coal tar of approved manufacture conforming to IS 290 shall be used. The tar, to every litre of
which 200 gm of unslaked lime has been added, shall be heated till it begins to boil. It must then be
taken off the fire and kerosene oil added to it slowly at the rate of one part of kerosene oil to six or more
parts by volume and stirred thoroughly. The addition of lime is for preventing the tar from running.
13.28.2 Coal Tarring New Surface

13. 28.2.1 Preparation of Surface : This shall be done as specified in 13.24.2 except that sand
papering is not necessary. Where iron work is to be painted it shall be free from scales and rust
before painting.
13.28.2.2 Application : The mixture shall be applied as hot as possible with a brush. The second
coat shall be applied only after the first coat has thoroughly dried up. Where possible, the article to
be tarred, shall be dipped in the hot mixture for better results. The quantity of tar to be used for the
first or second coat shall be not less than 0.16 and 0.12 litre per sqm respectively. Thinning with
kerosene oil shall be suitably done to ensure this.

13.28.2.3 The specifications described in 13.23 shall hold good in all other respects, so far as they
are applicable.
13.28.3 Coal Tarring old Surface

The work shall be done in the same manner as specified in 13.28.2 except that only one coat
using 0.12 litre per sqm. area shall be done.
13.29 SPRAY PAINTING WITH FLAT WALL PAINT ON NEW SURFACE

13.29.0 The work shall include a priming coat of ‘Distempering Primer’ or ‘Cement Primer’ as specified
in the description of the item. Flat wall Paint shall normally be applied on walls 12 months after their
completion, in which case Distemper primer will suffice. If the walls are to be painted earlier, the
primer coat shall consist of cement primer.
13.29.1 The primer and the flat wall Paint shall be of approved brand and manufacture and of the
required shade.
13.29.2 The surface shall be prepared as described in 13.20.1.
13.29.3 Application
13.29.3.1 Primer Coat : The specified primer shall be painted or sprayed over the surface in an
even and uniform layer.
13.29.3.2 Painting Coats : When the surface is dry, the spray painting with the wall Paint in uniform
and even layers will be done to the required number of coats. Each coat shall be allowed to dry
overnight and lightly rubbed with very fine grade of sand paper and loose particles brushed off
before the next coat is sprayed.
Spraying should be done only when dry condition prevails. During spraying the spray gun shall be
held perpendicular to the surface to be coated and shall be passed over the surface in a uniform sweeping
motion. Different air pressures and fan adjustment shall be tried so as to obtain the best application. The
Air pressure shall not be kept too high as otherwise the Paint will fog up and will be wasted.
At the end of the job, the spray gun shall be cleaned thoroughly so as to be free from dirt.
Incorrect adjustments shall be set right, as otherwise they will result in variable spray patterns, runs,
sags and uneven coats.
If after the final coat of wall Paints, the surface obtained is not upto the mark, further one or more
coats as required shall be given after rubbing down the surface and dusting off all loose particles to
obtain a smooth and even finish.
If the primer or wall Paint gets thickened during the application, it shall be thinned suitably with
the thinner recommended by the manufacture.
Adequate ventilation shall be provided to disperse spray fumes. Fitments and floor shall be
protected from the spray.
13.29.4 The specifications described in 13.23 shall hold good for all other details as far as applicable.
13.30 SPRAY PAINTING WITH FLAT PAINT ON OLD SURFACE

13.30.0 Where the old Paint is in sound condition, renewal shall be carried out as described below,
otherwise the old Paint shall be completely stripped and spray painting shall be carried out as over
new work. Such removal shall be paid for separately.

13.30.1 The flat wall Paint shall be of approved brand and manufacture and of required shade.

The surface shall be washed to remove dust and dirt. A mild detergent solution like soap water
shall be used for washing and the surface shall also be rubbed down lightly with abrasive paper
when dry. Any patches appearing on the surface shall first be touched up with a coat of Paint. These
shall be allowed to dry and then rubbed down lightly.
13.30.3 Application
The Paint shall then be applied with spraying machine in uniform and even layer. A second coat
shall be applied if considered necessary by the Engineer-in-Charge but only after the first coat is
complete dry and hard.
Spraying should be done only when dry condition prevails. During spraying the spray gun shall
be held perpendicular to the surface to be coated and shall be passed over the surface in uniform
sweeping motion. Different air pressures and fan adjustment shall be tried so as to obtain the best
application. The Air pressure shall not be kept too high as otherwise the Paint will fog up and will be
wasted. At the end of the job, the spray gun shall be cleaned thoroughly so as to be free from dirt.
Incorrect adjustments shall be set right, as otherwise they result in variable spray patterns, runs,
sags and uneven coats.
13.30.4 The specifications described in 13.22 shall hold good for all other details, as far as they are
applicable.
13.31 WALL PAINTING WITH PLASTIC EMULSION PAINT

13.31.0 The plastic emulsion Paint is not suitable for application on external, wood and iron surface
and surfaces which are liable to heavy condensation. These Paints are to be used on internal surfaces
except wooden and steel.
13.31.1 Plastic Emulsion Paint as per IS 5411 of approved brand and manufacture and of the required
shade shall be used.

13.31.2.1 The wall surface shall be prepared as specified in 13.23.3.
13.31.2.2 Application : The number of coats shall be as stipulated in the item. The Paint will be
applied in the usual manner with brush, spray or roller. The Paint dries by evaporation of the water
content and as soon as the water has evaporated the film gets hard and the next coat can be
applied. The time of drying varies from one hour on absorbent surfaces to 2 to 3 hours on non-
absorbent surfaces.
The thinning of emulsion is to be done with water and not with turpentine. Thinning with water will
be particularly required for the under coat which is applied on the absorbent surface. The quantity of
water to be added shall be as per manufacturer’s instructions.
The surface on finishing shall present a flat velvety smooth finish. If necessary more coats will be
applied till the surface presents a uniform appearance.
13.31.2.3 Precautions
(a) Old brushes if they are to be used with emulsion Paints, should be completely dried of
turpentine or oil Paints by washing in warm soap water.
Brushes should be quickly washed in water immediately after use and kept immersed in
water during break periods to prevent the Paint from hardening on the brush.

(b) In the preparation of wall for plastic emulsion painting, no oil base putties shall be used in
filling cracks, holes etc.
(c) Splashes on floors etc. shall be cleaned out without delay as they will be difficult to remove
after hardening.
(d) Washing of surfaces treated with emulsion Paints shall not be done within 3 to 4 weeks of
application.
13.31.2.4 Other details shall be as specified in 13.23 as far as they are applicable.

13. 31.3.1 Preparation of Surface : This shall be done, generally as specified in 13.24.2.1 except
that the surface before application of Paint shall be flattened well to get the proper flat velvety finish
after painting.
13.31.3.2 Application : The number of coats to be applied shall be as in description of item.

The application shall be as specified in 13.31.2.2 except that thinning with water shall not normally
be required.
13.31.3.3 Other details shall be as specified in 13.23 as far as applicable.
13.32 PAINTING WITH SYNTHETIC ENAMEL PAINT

13.32.1 Synthetic Enamel Paint (conforming to IS 2933) of approved brand and manufacture and of
the required colour shall be used for the top coat and an undercoat of ordinary Paint of shade to
match the top coat as recommended by the same manufacturer as far the top coat shall be used.

13.32.2.1 Preparation of surface shall be as specified in 13.24.2 as the case may be.
13.32.2.2 Application : The number of coats including the undercoat shall be as stipulated in the item.
(a) Under Coat : One coat of the specified ordinary Paint of shade suited to the shade of the top
coat, shall be applied and allowed to dry overnight. It shall be rubbed next day with the finest
grade of wet abrasive paper to ensure a smooth and even surface, free from brush marks
and all loose particles dusted off.
(b) Top Coat : Top coats of synthetic enamel Paint of desired shade shall be applied after the
undercoat is thoroughly dry. Additional finishing coats shall be applied if found necessary to
ensure properly uniform glossy surface.

13.32.3.1 Preparation of Surface : Where the existing Paint is firm and sound it shall be cleaned of
grease, smoke etc. and rubbed with sand paper to remove all loose particles dusted off. All patches
and cracks shall then be treated with stopping and filler prepared with the specified Paint. The
surface shall again be rubbed and made smooth and uniform.
If the old paint is blistered and flaked it will be necessary to completely remove the same as
described in para 13.41. Such removal shall be paid for separately and the painting shall be treated
as on new surface.

13.32.3.2 Painting : The number of coats as stipulated in the item shall be applied with synthetic
enamel Paint. Each coat shall be allowed to dry and rubbed down smooth with very fine wet abrasive
paper, to get an even glossy surface. If however, the surface is not satisfactory additional coats as
required shall be applied to get correct finish.
13.32.3.3 Other details shall be specified in 13.22 as far as they are applicable.
13.33 PAINTING WITH ALUMINIUM PAINT

13.33.1 Aluminium Paint shall be (conforming to IS 2339) of approved brand and manufacture. The
Paint comes in compact dual container with the paste and the medium separately.
The two shall be mixed together to proper consistency before use.

13.33.2.1 Steel Work (New Surfaces) : All rust and scales shall be removed by scraping or brushing
with steel wire brushes and then smoothened with sand paper. The surface shall be thoroughly
cleaned of dust.
13.33.2.2 C.G.S. Sheets (New Surfaces) : The preparation of surface shall be as specified in 13.25.1.1.
13.33.2.3 Steel Work or C.G.S. sheets (Old Surfaces): The specifications shall be as described in
13.25.1.2.
13.33.3 Application
The number of coats to be applied shall be as given in the item. Each coat shall be allowed to dry
for 24 hours and lightly rubbed down with fine grade sand paper and dusted off before the next coat
is applied. The finished surface shall present an even and uniform appearance.
As aluminium paste is likely to settle in the container, care shall be taken to frequently stir the
Paint during used. Also the Paint shall be applied and laid off quickly, as surface is otherwise not
easily finished.
13.33.4 Other details shall be as specified in 13.23 as far as they are applicable.
13.34 PAINTING WITH ACID PROOF PAINT
13.34.1 Acid proof Paint of approved brand and manufacture and of the required shade shall be used.
13.34.2 Preparation of surface and application shall be as specified under 13.32 for new/old surface
as the case may be.
13.34.3 Other details shall be as specified in 13.23 as far as they are applicable.
13.35 PAINTING WITH ANTI-CORROSIVE BITUMASTIC PAINT

13.35.1 Ready mixed Paint (conforming to IS 158) shall be of approved brand and manufacture. It
shall be black, lead free, acid-alkali-heat-water resistant.
13.35.2 Preparation of surface and application shall be as specified in 13.32 for painting on new or
old surfaces as the case may be.
The drying time between consecutive coats, however, shall be not less than 3 hours.
13.35.3 Other details shall be as specified in 13.23 as far as applicable.

13.36 FLOOR PAINTING
13.36.1 Floor Paint of approved brand and manufacture and of the required colour shall be used.

All dirt, grease shall be removed from the floor by wiping with rags, soaked in turpentine and
scraping where necessary and then washing with warm water, containing caustic soda or washing
soda in solution. The floor should then be rinsed thoroughly with water and dried. Cracks and holes
shall then be filled with specified filler as recommended by the manufacturer and rubbed smooth.
It should be noted that the painting with floor paints shall not be done over concrete surfaces less
than two years old.
Old surface shall be prepared as specified in 13.32.3.1
13.36.3 Application
The number of coats as in the description of the item shall be applied. Each coat shall be allowed
to dry for not less than 24 hours before the next coat is applied. The flooring should not be brought
into use for a week after final coat so that the painted surface can thoroughly harden.
13.36.4 Measurement
Measurements shall be as per actual length and breadth being measured correct to a cm. The
details given under 13.23.6 shall hold good as far as applicable.
13.37 VARNISHING
13.37.0 Ordinary copal varnish or superior quality spray varnish shall be used. The work includes
sizing of transparent wood filler.
13.37.1 Varnish (conforming to IS 347 for the finishing and undercoats shall be of the approved
manufacturer.
13.37.2 Varnishing on New Surfaces

13.37.2.1 Preparation of Surface : New wood work to be varnished shall have been finished smooth
with a carpenter’s plane. Knots shall be cut to a slight depth. Cracks and holes shall be cleaned of
dust. The knots, cracks etc. shall then be filled in with wood putty made as follows:
On a piece of wood say 20 x 15 cm face and on the side where cross grains appear, a small
quantity of glue size shall be poured and the surface scraped with the edge of a fine carpenter’s
chisel. Very fine wood powder shall be mixed with the glue and the stiff paste thus formed shall be
used for the filling.
The fillings when dry shall be rubbed down with a carpenter’s file and then the entire surface
shall be rubbed down perfectly smooth with medium grained and fine sand papers and wiped with dry
clean cloth so that it presents uniform appearance. In no case shall sand papers be rubbed across
the grains, as in this case even the finest marks will be visible when the varnishing is applied.
13.37.2.2 Sizing or Transparent Wood Filler Coat : The surface shall then be treated with either
glue sizing or with transparent wood filler coat as stipulated in the description of item.
(a) Sizing : When sizing is stipulated, an application of thin clean size shall be applied hot on the
surface. When dry, the surface shall be rubbed down smooth with sand paper and cleaned.
It shall then be given another application of glue size nearly cold. The sized wood work shall

again be rubbed down smoothly with fine sand paper and cleaned. The surface shall be
perfectly dry and all dust shall be removed not only from the surface but also from the edges
and joints before varnishing is commenced. If the wood work is to be stained, the staining
colour shall be mixed with the second coat of the size which must be applied evenly and
quickly keeping the colour on the flow.
Any joining up with work already dry will show badly. The object of application of the glue size
is to seal the pores in wood to prevent absorption of the oil in the varnish.
Glue sizing is inadvisable on floors, table tops and other horizontal surfaces likely to carry wet
household untensils which are likely to disturb the size coatings and thus expose bare wood.
Where glue sizing is omitted to be done the rate for the work shall be suitably reduced.
(b) Transparent Wood Filler Coat : Where instead of glue sizing, transparent wood filler application
is stipulated in the item, then the surface prepared as described in 13.37.2.1 shall be given
as application of the filler with brush or rag in such a way that the filler fills up all the pores
and indentations and levels up the surface. It shall be allowed to dry for 24 hours. Then it
shall be cut and rubbed with emery paper so that the surface of the wood is laid bare, with the
filler only in the pores and crevices of the wood.
13.37.2.3 Application of Varnish : The number of coats to be applied shall be as stipulated in the
des-cription of the item.
The undercoat shall be with a flatting varnish. This dries hard and brittle and when cut and
rubbed down to produce a smooth surface enhances the gloss of the finishing varnish. The top coat
shall be given with stipulated brand of finishing varnish.
The varnish shall be applied liberally with a full brush and spread evenly with short light strokes
to avoid frothing. If the work is vertical the varnish shall be crossed and recrossed and then laid off,
latter being finished on the upstrokes so that varnish, as it sets, flows down and eliminates brush
marks, the above process will constitute one coat. If the surface is horizontal, varnish shall be worked
in every direction, with light quick strokes and finish in one definite direction so that it will set without
showing brush marks, in handling and applying varnish care should be taken to avoid forming froth
or air bubbles. Brushes and containers shall be kept scrupulously clean.
Rubbing down and flatting the surface shall be done after each coat except the final coat with fine
sand paper.
The work shall be allowed to dry away from droughts and damp air. The finished surface shall
then present a uniform appearance and fine glossy surface free from streaks, blister etc.
Any varnish left over in the small container shall not be poured back into the stock tin, as it will
render the latter unfit for use.
Special fine haired varnishing brushes shall be used and not ordinary Paint brushes. Brushes
shall be well worn and perfectly clean.

13.37.3 Varnishing on Old Surface
13.37.3.1 Preparation of Surface : If the old varnished surface is firm and sound it shall be cleaned
of grease and dirt with turpentine and then rubbed with wet sand paper until the surface is clean and
smooth. It shall be dried and wiped clean with a soft cloth. Knots, holes and cracks shall be stopped
as specified in 13.37.2.1. The entire surface shall then be rubbed down smooth with sand paper and
wiped clean.
If the old varnished surface is peeled or cracked then it will be necessary to remove the entire
varnish as described in para 13.41 and such removal shall be paid for separately outside the rate for
varnishing. Further the varnishing itself will have to be done like new work and will be paid for as such.
13.37.3.2 Application : The specification shall be same as described in 13.37.2.3 as far as applicable
except that the coats to be applied will be with the stipulated quality of varnish for finishing coat.
13.37A MELAMINE POLISH

13.37A.1 Material
Melamine is an organic compound that is often combined with formaldehyde to produce melamine
resin, a synthetic polymer that is fire resistant and heat tolerant. The resin is a versatile material that
has a highly stable structure. It is a closed pore polish i.e. it makes the wood non-breathable
product that protects wood from mainly hot and cold surfaces placed over it.
13.37A.2 Polishing Old Surface

13.27A.2.1 Preparation of surface
The surface shall be thoroughly cleaned. All unevenness shall be rubbed down smooth with
sand paper and shall be well dusted. Surface must be dry, free from dust, oil, wax, greases etc.
Mix melamine (matt or gloss) base with the catalyst in the specified ratio as per manufacturers
specification. Add melamine thinner upto 30% (as specified by the manufacturer) by volume of mixture.
Stir it and allow it to mature for 2-3 minutes. The melamine is sprayed, using spray gun pressure of
45-55 psi, from a distance of 7"-10" from substrate.
Precaution : Avoid eye contact, use of mask is mandatory during whole process.
Measurements, Rate and other details shall be as specified in 13.23 as far as they are applicable.
13.38 FRENCH SPIRIT POLISHING

13.38.1 Pure shellac conforming to IS 16 varying from pale orange to lemon yellow colour, free from
resin or dirt shall be dissolved in methylated spirit at the rate of 140 gm of shellac to 1 litre of spirit.
Suitable pigment shall be added to get the required shade. Ready made polish conforming to IS 348
can also be used.
13.38.2 Polishing New Surface

13.38.2.1 Preparation of Surface : The surface shall be cleaned. All unevenness shall be rubbed
down smooth with sand paper and well dusted. Knots if visible shall be covered with a preparation of
red lead and glue size laid on while hot. Holes and indentations on the surface shall be stopped with
glazier’s putty. The surface shall then be given a coat of wood filler made by mixing whiting (ground
chalk) in methylated spirit at the rate of 1.5 Kg of whiting per litre of spirit. The surface shall again be
rubbed down perfectly smooth with glass paper and wiped clean.

13.38.2.2 Application : The number of coats of polish to be applied shall be as described in the item.
A pad of woolen cloth covered by a fine cloth shall be used to apply the polish. The pad shall be moistened
with the polish and rubbed hard on the wood, in a series of overlapping circles applying the mixture sparingly
but uniformly over the entire area to give an even level surface. A trace of linseed oil on the face of the pad
facilitates this operation. The surface shall be allowed to dry and the remaining coats applied in the same way.
To finish off, the pad shall be covered with a fresh piece of clean fine cotton cloth slightly damped with
methylated spirit and rubbed lightly and quickly with circular motions. The finished surface shall have a
uniform texture and high gloss.
13.38.2.3 Measurements, Rate and other details shall be as specified in 13.23 as far as they are applicable.
13.38.3 Polishing Old Surface

13.38.3.1 Preparation of Surface : If the old polished surface is not much soiled it shall be cleaned of grease
and dirt by rubbing with turpentine and then rubbed with fine sand paper.
If the old polished surface is much soiled then it will be necessary to remove the entire polish as described
in 13.41 and such removal shall be paid for separately outside the rate of polishing. Further the polishing itself
will have to do done like new work and will be paid for as such.
13.38.3.2 Application : The specifications shall be same as described in 13.38.2.2 as far as applicable.
13.38.3.3 Measurements, Rate and other details shall be as specified in 13.23 as far as they are applicable.
13.39 BEES WAXING OR POLISHING WITH READY MADE WAX POLISH

13.39.1 The polishing shall be done with bees waxing prepared locally or with readymade wax polish of
approved brand and manufacture, as stipulated in the description of item.
Where bees waxing is to be prepared locally, the following specifications for the same shall apply.
Pure bees wax free from paraffin or stearine adulterants shall be used. Its specific gravity shall be 0.965
to 0.969 and melting point shall be 63 degree C. The polish shall be prepared from a mixture of bees wax,
linseed oil, turpentine and varnish in the ratio of 2 : 1.5 : 1 : 0.5 by weight.
The bees wax and boiled linseed oil shall be heated over a slow fire. When the wax is completely dissolved
the mixture shall be cooled till it is just warm and turpentine and varnish added to it in the required proportions
and the entire mixture shall be well stirred.
13.39.2 Waxing New Surface

13.39.2.1 Preparation of Surface : Preparation of surface shall be as described in 13.37.2.1 with the exception
that knotting, holes and cracks shall be stopped with a mixture of fine saw dust formed of the wood being
treated, beaten up with sufficient bees wax to give it cohesion.
13.39.2.2 Application : The polish shall be applied evenly with a clean soft pad of cotton cloth in such a way
that the surface is completely and fully covered. The surface is then rubbed continuously for half an hour.
When the surface is quite dry, a second coat shall be applied in the same manner and rubbed continuously
for one hour or until the surface is dry.
The final coat shall then be applied and rubbed for two hours (more if necessary) until the surface has
assumed a uniform gloss and is dry, showing no sign of stickiness.
The final polish depends, largely on the amount of rubbing which should be continuous and with uniform
pressure with frequent changes in the direction.

13.39.3 Waxing Old Surfaces
13.39.3.1 Preparation of Surface : The wood work shall be cleaned of all smoke and grease by washing with
lime water. The surface shall then be washed with soap and completely dried. Then it shall be prepared
smooth as specified in 13.37.2.1.
13.39.3.2 Application : The polish shall be applied in the manner specified in 13.39.2.2. In this case one or
two coats shall be applied as necessary to get uniform gloss, instead of three coats in the case of new work.
13.40 LETTERING WITH PAINT

13.40.1 Black, Japan Paint (conforming to IS 341) or ready mixed Paint as ordered by the Engineer-in-Charge
shall be used. The Paint shall be of approved brand and manufacture. Ordinary ready mixed Paint shall be of
the shade required by the Engineer-in-Charge.
13.40.2 Lettering on New Surface

13.40.2.1 Application : The letters and figures shall be to the heights and width as ordered by the Engineer-
in-Charge. These shall be stenciled or drawn in pencil and got approved before painting. They shall be of
uniform size and finished neatly. The edges shall be straight or in pleasant smooth curves. The thickness of
the lettering shall be as approved by the Engineer-in-Charge. Lettering shall be vertical or slanting as required.
Two or more coats of Paint shall be applied till uniform colour and glossy finish are obtained.
13.40.2.2 Measurements : Measurements shall be taken in terms of letter cm (the measurement relates to
the vertical height of the lettering). The letter heights shall be measured correct to a cm. Dots, dashes,
punctuations and other similar marks or lines shall not be measured for payment.
In Devanagari Script Dots & Matras occurring with the letters shall not be measured. Half letter shall be
measured as full letter. The height of letters shall be measured excluding the Matras projecting above the
heading and matras below the letters.
13.40.2.3 Rate : Rate shall include the cost of all labour and materials involved in the operations described
above. The rate per cm height of letter shall hold good irrespective of the width of the letters or figures or the
thickness of the lettering.
The same rate will apply irrespective of whether black Japan or ready mixed Paint of any shade as
required is used.
13.40.3 Relettering on Old Surface

13.40.3.1 Painting shall be done over the existing letters and shall accurately follow their lines and curves.
One or more coat of Paints shall be applied till a uniform colour and glossy finish is obtained.
13.40.3.2 Measurements and Rate shall be as specified under 13.40.2.
13.41 REMOVING OLD PAINT
13.41.1 With Patent Paint Remover

13.41.1.1 Patent Paint removers shall consist of volatile organic liquids thickened with waxes and other
ingredients to retard the evaporation of the liquid and to enable a substantial layer of remover to be applied to
the surface. The Paint remover shall be of a brand and manufacture approved by the Engineer-in-Charge. It
shall be free from alkaline matter and non- caustic so that it can be handled by workmen without injury. It shall
be of non inflammable quality as far as possible.

13.41.1.2 Application : Paint remover shall be used where burning off with blow lamp is not suitable.
The Paint remover shall be applied liberally with a brush and allowed to remain on the surface for a
period depending on the particular brand of remover used and on the thickness of the Paint coating
to be removed. When the Paint film lifts and wrinkles under the action of the remover it shall be
stripped with a sharp instrument. If the film is not thoroughly removed a second coat of remover may
be applied if necessary over such patches and then the film thoroughly scrapped.
After the surface has been stripped, it shall be washed down with mineral turpentine to remove all
traces of paraffin wax, which forms one of the ingredients of patent Paint remover and which if left in
place will prevent the Paint from drying.
The cleaned surface shall be suitably prepared for application of Paint or other finish.
13.41.1.3 Precautions : Where the Paint remover used is of the inflammable type, suitable precaution
against risk of fire shall be taken.
Neighbouring painted surfaces which are not to be treated should be properly protected from
contact with Paint remover.
13.41.1.4 Preparation of Surface : The surface shall then be prepared as described in 13.24.2.
13.41.1.5 Measurements : Specification for 13.23.6 shall hold good.
13.41.1.6 Rate : Rate shall include the cost of all labour and materials involved in all operations
described above.
13.41.1.7 Other details shall be as specified 13.23 as far as possible.
13.41.2 With Caustic Soda Solution

13. 41.2.1 Application : Caustic soda dissolved with 48 times its volume of water shall be applied to
the old Paint with a brush and when the Paint film lifts and wrinkles it shall be thoroughly scrapped of
in the same way as described in 13.41.1.2. After the surface has been stripped thoroughly, it shall be
rinsed with several chances of clean water to remove all traces of alkali, which if allowed to remain
are liable to spoil the new Paint applied over it. A little acetic acid or vinegar added to the final change
of rinsing water helps to neutralize any remaining alkali.
13.41.2.2 Precautions : Caustic soda as its name implies is a corrosive liquid and care should be
taken to see that no liquid spills over the skin or clothing.
13.41.2.3 Preparation of Surface, Measurements, Rate and other details shall be as specified
under 13.41.1.
13.41.3 With Blow Lamp

13.41.3.1 The Paint shall be removed either with a blow lamp or with air acetylene equipment. The
flame shall be allowed to play upon the Paint just enough to soften it without charring either the Paint
or the background. The softened Paint shall then be removed with a stripping knife following the
flame as it is moved up the surface.
Burning off shall begin at the bottom of the vertical surface and shall proceed upwards.

13.41.3.2 Precautions : Removal with blow lamp shall not be done on narrow or carved under cut
surfaces or where there is risk of damage to neighbouring materials such as panes in glazed windows.
13.41.3.3 Preparation of surface, Measurements, Rate and other details shall be as described under
13.41.1.
Neighbouring painted surfaces which are not to be treated should be properly protected from
contact with Paint remover.
13.42 WASHED STONE GRIT PLASTER

13.42.1 Scaffolding shall be as specified in 13.1.1.
13.42.2 Preparation of surface shall be as specified in 13.1.2 and 13.4.2.
13.42.3 Materials
13.42.3.1 Stone chippings obtained by crushing hard stone shall be free of dust and deleterious
material. 10 mm nominal size stone chippings, where specified, shall pass 100% through 12.5 mm
sieve and fully retained on 6.3 mm sieve. Stone chippings shall be thoroughly washed with water and
sieved before use.
13. 42.3.2 Mortar : Cement mortar for under coat and cement mortar to be mixed with stone chippings
for top coat shall be as specified in 3.5.

13.42.4.1 12 mm Under Coat : Under coat of cement mortar 1:4 (1 cement : 4 coarse sand) shall be
applied as specified in 13.1.3 except that the finishing, after the mortar has been brought to level
with the wooden straight edge, shall be done with wooden float only. The surface shall be further
roughened by furrowing with a scratching tool. Furrowing shall be done diagonally both ways and
shall be about 2 mm deep to provide a key for the top coat. The scratched lines shall not be more
than 10 cm apart. The surface shall be kept wet till top coat is applied.
13.42.4.2 15 mm Top Coat : Top coat comprising cement mortar and stone chippings shall have an
overall proportion of 1:0.5:2 (1 cement : 0.5 coarse sand : 2 stone chippings 10 mm nominal size) or
as specified. The top coat shall be applied a day or two after the under coat has taken the initial set.
The surface of the under coat shall be cleaned and a coat of cement slurry at 2 kg of cement per sqm
shall be applied before the application of coat. The top coat shall be applied in uniform thickness on
the under coat after the application of slurry and sufficiently pressed with wooden float for proper
bonding with the under coat. Vacant space, if any shall be filled with the specified mix.
13.42.5 Finish
The top coat of plaster shall be finished to a true and plumb surface. The surface shall be tested
frequently as the work proceeds with a true straight edge not less than 2.5 m long and with plumb
bobs. All horizontal lines and surfaces shall be tested with a level and all jambs and corners with a
plumb bob as the work proceeds. All the corners angles and junctions shall be truly vertical or
horizontal as the case may be. Rounding or chamfering of corners junctions etc. Where required
shall be true to template.
Finished surface of the top coat after the mix has taken the initial set, shall be scrubbed and
washed with suitable brushes and plain water. Scrubbing and washing shall continue till the stone
chippings are sufficiently exposed. Stone chippings which may come out while scrubbing shall be
replaced using the specified mortar mix. A sample of the washed stone grit plaster shall be got
approved from the Engineer-in-Charge.

13.42.6 Grooves
Grooves of size 15 mm x 15 mm or as specified shall be provided as shown on the drawing or as
required by the Engineer-in- Charge. Tapered wooden battens to match the size and shape of the
grooves shall be fixed on the under coat with nails before the application of the top coat and these
shall be removed carefully so that the edges of the panels of top coat are not damaged. Damage, if
any, shall be made good by the contractor.
13.42.7 Curing
Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept wet for a
period of seven days. During this period, it shall be suitably protected from all damages at the
contractor’s expense by such means as the Engineer-in-Charge may approve.
13.42.8.1 Length and breadth shall be measured correct to the nearest cm and the area shall be
calculated in sqm correct to two places of decimal.
13.42.8.2 Measurements shall be taken for the work actually done with deductions for all openings
and addition for all jambs soffits and sills. However, no deduction is to be made for the grooves
provided as specified in 13.42.6.
13.42.8.3 Washed stone grit plaster on circular surfaces not exceeding 6 m in radius and on external
surfaces at a height greater than 10 m shall be measured separately.
13.42.9 Rates
The rates shall include the cost of all labour and materials involved in all the operations described
above except for providing grooves. The length of grooves shall be measured in running metres and
paid for separately.
13.43 GYPSUM LIGHT WEIGHT PLASTER

13.43.1 Scaffolding shall be as specified in 13.11.
13.43.2 Preparation of surface shall be as specified in 13.1.2 and 13.4.2.
13.43.3 Materials
13.43.3.1 Premixed light weight plasters essentially consist of retarded hemihydrate gypsum plaster
and light weight aggregate which are characterized by low density, high thermal insulation and sound
absorption properties. Other additions may be incorporated to impart desired properties. The physical
and chemical requirements shall conform to IS 2547 (Pt. II).
13.43.3.2 The minimum recommended water-premixed plaster ratio is 1:2 as per standard practice
or as recommended by the manufacturers.

13.43.4.1 Application of plaster shall be as specified in 13.1.4.1 to 13.1.4.4.
13.43.5 Thickness
Where the thickness required, as per description of the item is 12 mm, the average thickness of
the plaster shall not be less than 12 mm whether wall treated is of brick/block/RCC work.
13.43.6 Finish
The plaster shall be finished as specified in 13.1.7.

13.43.7 Measurement
Measurement of plaster shall be as specified in 13.1.9.1 to 13.1.9.9.
13.43.8 Rate
Rate shall include the cost of all labour & material involved in all the operations described above.
13.44 PAINTING CAST IRON RAIN WATER, SOIL, WASTE AND VENT PIPES AND FITTINGS
13.44.1 The primer shall be prepared on site or shall be of approved brand and manufacture as
specified in the item.
Paint shall be anti-corrosive bitumastic paint aluminium paint or other type of paint as specified in
the description of the item.
13.44.2 Painting New Surface

13.44.2.1 Preparation of Surface: The surface shall be prepared for priming coat as described in
13.34.2.2.
13.44.2.2 Application: The number of coat of painting over the priming coat shall be as stipulated in
the description of the item. The application of paint over priming coat shall be carried out as specified
in 13.35.
13.44.2.3 Measurements: Measurements will be taken over the finished line of pipe including specials
etc. in running metres, correct to a cm.
Pipes of different diameters of bore shall be measured and paid for separately.
Specials and fittings such as holder bat clamps, plugs etc. will not be measured separately.
13.44.2.4 Rate: The rate shall include the cost of all materials and labour involved in all the operations
described above, including painting of all specials and fittings.
13.44.2.5 Specifications described in 13.22 shall hold good as far as they are applicable.

13.44.3.1 The surface shall be prepared as specified in 13.25.1.2.
13.44.3.2 The specifications for application shall be as described in 13.25.2.
13.44.3.3 Measurements, rate and other details shall be as specified in 13.23.6.
Note: Clause 13.44 brought from Sub Head 14 (Repairs to buildings) clause no 14.24.
13.45 PAINTING WITH WOOD PRESERVATIVE

13.45.1 Oil type wood preservative of specified quality and approved make, conforming to IS 218
shall be used. Generally, it shall be creosote oil type-I or anthracene oil.

13.45.2.1 Preparation of Surface: Painting shall be done only when the surface is perfectly dry to
permit of good absorption. All dirt, dust or other foreign matter shall be removed from the surface to
be painted. All roughness shall be sand papered and cleaned.

13.45.2.2 Application: The preservative shall be applied liberally with a stout brush and not daubed
with rags or cotton waste. It shall be applied with a pencil brush at the joints of the wood work. The
first coat shall be allowed at least 24 hours to soak in before the second (the final) coat is applied.
The second coat shall be applied in the same manner as the first coat. The excess of preservative
which does not soak into the wood shall be wiped off with a clean dry piece of cloth.
13.45.2.3 The specifications described in 13.23 shall hold good in so far as they are applicable.

The work shall be done in the same manner as on new surface except that only one coat shall
be done.
Note: Clause 13.45 brought from Sub Head 14 (Repairs to buildings) clause no 14.25
13.46 WALL PAINTING WITH PLASTIC EMULSION PAINT

13.46.0 The plastic emulsion paint is not suitable for application on external, wood and iron surface
and surfaces which are liable to heavy condensation. These paints are to be used on internal surfaces
except wooden and steel.
13.46.1 Plastic emulsion paint as per IS 5411 of approved brand and manufacture and of the required
shade shall be used.

13.46.2.1 The wall surface shall be prepared as specified in 13.31.
13.46.2.2 Application : The number of coats shall be as stipulated in the item. The paint will be
applied in the usual manner with brush, spray or roller. The paint dries by evaporation of the water
content and as soon as the water has evaporated the film gets hard and the next coat can be
applied. The time of drying varies from one hour on absorbent surfaces to 2 to 3 hours on non-
absorbent surfaces.
The thinning of emulsion is to be done with water and not with turpentine. Thinning with water will
be particularly required for the under coat which is applied on the absorbent surface. The quantity of
water to be added shall be as per manufacturer’s instructions.
The surface on finishing shall present a flat velvety smooth finish. If necessary more coats will be
applied till the surface presents a uniform appearance.
13.46.2.3 Precautions
(a) Old brushes if they are to be used with emulsion paints, should be completely dried of
turpentine or oil paints by washing in warm soap water.
Brushes should be quickly washed in water immediately after use and kept immersed in
water during break periods to prevent the paint from hardening on the brush.
(b) In the preparation of wall for plastic emulsion painting, no oil base putties shall be used in
filling cracks, holes etc.
(c) Splashes on floors etc. shall be cleaned out without delay as they will be difficult to remove
after hardening.
(d) Washing of surfaces treated with emulsion paints shall not be done within 3 to 4 weeks of
application.

13.46.3.1 Preparation of Surface : This shall be done, generally as specified in 13.31.3.1 except
that the surface before application of paint shall be flattened well to get the proper flat velvety finish
after painting.
13.46.3.2 Application : The number of coats to be applied shall be as in description of item.
The application shall be as specified in 13.31.3.2 except that thinning with water shall not normally
be required.
13.46.3.3 Other details shall be as specified in 13.23 as far as applicable.
13.47 PAINTING WITH SYNTHETIC ENAMEL PAINT

13.47.1 Synthetic enamel paint (conforming to IS 2932) of approved brand and manufacture and of
the required colour shall be used for the top coat and an undercoat of ordinary paint of shade to
match the top coat as recommended by the same manufacturer as far the top coat shall be used.

13.47.2.1 Preparation of surface shall be as specified in 13.25.1.1 as the case may be.
13.47.2.2 Application : The number of coats including the undercoat shall be as stipulated in the item.
(a) Under Coat : One coat of the specified ordinary paint of shade suited to the shade of the
top coat, shall be applied and allowed to dry overnight. It shall be rubbed next day with the
finest grade of wet abrasive paper to ensure a smooth and even surface, free from brush
marks and all loose particles dusted off.
(b) Top Coat : Top coats of synthetic enamel paint of desired shade shall be applied after the
undercoat is thoroughly dry. Additional finishing coats shall be applied if found necessary to
ensure properly uniform glossy surface.

13.47.3.1 Preparation of Surface : Where the existing paint is firm and sound it shall be cleaned of
grease, smoke etc. and rubbed with sand paper to remove all loose particles dusted off. All patches
and cracks shall then be treated with stopping and filler prepared with the specified paint. The
surface shall again be rubbed and made smooth and uniform.
If the old paint is blistered and flaked it will be necessary to completely remove the same as
described in para 13.41. Such removal shall be paid for separately and the painting shall be treated
as on new surface.
13.47.3.2 Painting : The number of coats as stipulated in the item shall be applied with synthetic
enamel paint. Each coat shall be allowed to dry and rubbed down smooth with very fine wet abrasive
paper, to get an even glossy surface. If however, the surface is not satisfactory additional coats as
required shall be applied to get correct finish.
13.47.3.3 Other details shall be specified in 13.23 as far as they are applicable.

13.48 PAINTING WITH ALUMINIUM PAINT
13.48.1 Aluminium paint shall be (conforming to IS 2339) of approved brand and manufacture. The
paint comes in compact dual container with the paste and the medium separately.
The two shall be mixed together to proper consistency before use.

13.48.2.1 Steel Work (New Surfaces) : All rust and scales shall be removed by scraping or brushing
with steel wire brushes and then smoothened with sand paper. The surface shall be thoroughly
cleaned of dust.
13.48.2.2 C.G.S. Sheets (New Surfaces) : The preparation of surface shall be as specified in
13.33.2.
13.48.2.3 Steel Work or C.G.S. Sheets (Old Surfaces): The specifications shall be as described
in 13.33.2.3.
13.48.3 Application
The number of coats to be applied shall be as given in the item. Each coat shall be allowed to dry
for 24 hours and lightly rubbed down with fine grade sand paper and dusted off before the next coat
is applied. The finished surface shall present an even and uniform appearance.
As aluminium paste is likely to settle in the container, care shall be taken to frequently stir the
paint during used. Also the paint shall be applied and laid off quickly, as surface is otherwise not
easily finished.

SUB HEAD : 14.0
REPAIRS TO BUILDINGS
681
CONTENTS
14.1 Repairs to Plaster 688
14.2 Fixing Door, Window or Clerestory Window 689

Chowkhat in existing opening
14.3 Fixing Chowkhats in existing opening in Bricks/ 690

RCC Wall with dash Fastners
14.4 Making opening in the Masonry Construction and 691

Fixing Chowkhats for Doors, Window and
Clerestory Windows
14.5 Renewing Floating Glass Panes with Putty and Nails 692
14.6 Renewing Floating Glass Panes with Wooden Fillets 693
14.7 Renewing Floating Glass Panes & Refixing Existing 693

Wooden Fillets
14.8 Providing New Wooden Fillets 693
14.9 Renewal of Old Putty of Glass Panes 694
14.10 Refixing Old Glass Panes with Putty and Nails. 694
14.11 Fixing Old Glass Panes with Wooden Fillets. 694
14.12 Fixing Fan Clamps in Existing RCC Slabs 694
14.13 Regrading of Mud Phuska Terracing 694
14.14 Replacing Red or White Sand Stone Slabs in Roofing 695
14.15 Renewing Wooden Battens / Beams in Roofs 696
14.16 Panelled Glazed or Panelled and Glazed Shutters 696
14.17 Trellis (Jaffri) Work 700
14.18 Fittings 700
14.19 White Wash with Lime (Shifted to 13.14) 704
683 SUB HEAD 14.0 : REPAIRS TO BUILDINGS

14.20 Dry Distemper (Shifted to 13.18) 704
14.21 Oil Emulsion (Oil Bound) Washable Distempering 704

(Shifted to 13.19)
14.22 Cement Paint (Shifted to 13.21) 704
14.23 Painting Readymade Mixed Paint over G.S. Sheets 704
14.24 Painting Cast Iron Rain Water, Soil, Waste and Vent 705
Pipes and Fittings (Shifted to 13.44)
14.25 Painting with Wood Preservative (Shifted to 13.45) 705
14.26 Wall Painting with Plastic Emulsion Paint 705

(Shifted to 13.46)
14.27 Painting with Enamel Paint 705
14.28 Painting with Synthetic Enamel Paint 705

(Shifted to 13.47)
14.29 Painting with Aluminium Paint (Shifted to 13.48) 705
14.30 Painting with Anti Corrosive Bitumastic Paint 705

(Shifted to 13.35)
14.31 Varnishing 705
14.32 Lettering with Paint (Shifted to 13.40) 707
14.33 Double Scaffolding 707
14.34 Fixing Old Wind Ties 707
14.35 Brick work in mud mortar 707
14.36 Brass curtain rods 708
14.37 Fixing M.S round or square bar in wooden frame 709

of window
14.38 Providing wooden karries for roofing 709
14.39 Double scaffolding system upto seven storey height 709

made with M.S tube

14.40 Repair to plaster in patches. 710
14.41.1 Cleaning of water storage tanks 710
14.41.2 Cleaning and de-silting of gully trap 710
14.41.3 Cleaning of chocked sewer line 711
14.41.4 Cleaning of underground Sump, Over Head 711

R.C.C. Tank
14.42 Disconnecting damaged overhead/terrace 712
14.43 Replacement of old damaged W.C. seats 712
14.44 Cutting holes of required size in brick masonry wall 712
14.45 Dismantling W.C. pan of all sizes 712
14.46 Hacking of C.C. flooring 713
14.47 Dismantling 15 to 40mm dia G.I. pipe 713
14.48 Taking out existing wooden door shutter and 713

re-fixing the same after repairs
14.49 Water proofing treatment with app (atactic 713

polypropylene polymeric) membrane
14.50 Five layered water proofing treatment with atactic 717

polypropylene polymer modified prefabricated
membrane
14.51 Extra for covering of app modified prefabricated 720

membrane with geotextile
14.52 Providing round the clock security guard 720

without gun
14.53 Providing round the clock security guard with gun 720
Fig. 14.1 Fixing of Fan Clamps in Existing R.C.C. Slabs 721
Fig. 14.2 Terminology Timber Door, Window & Ventilator 722

Components
Fig. 14.3 Flush Bolts 723

Fig. 14.4 Flush Door Stopper 724
Fig. 14.5 Window Stay 725
Fig. 14.6 Typical details of Multi-Stage Shuttering 726
Fig. 14.7 Five Course Water Proofing Treatment with 727

APP Modified Polymeric Membrane
Fig. 14.8 Grading Chajja with Cement Mortar 1:3/1:4 727
Fig. 14.9 Grading Roof Slab with Cement Concrete 728
Fig. 14.10 Water Proofing 728
Fig. 14.11 Five Layers Water-Proofing Treatment with 729

APP Modified Prefabricated Membrane


1. IS 419 Specifications for Putty for use in Window Frames
2. IS 14900 Specifications for Transparent Float Glass

14.0 REPAIRS TO BUILDINGS
14.1 REPAIRS TO PLASTER
14.1.0 The work includes cutting the patch and preparing the wall surface. Patches of 2.50 square
metres and less in area shall be measured under item of ‘Repairs to Plaster’ under this sub-head.
Plastering in patches over 2.5 square metres in area shall be paid for at the rate as applicable to new
work under sub head ‘Finishing’.
14.1.1 Scaffolding
Scaffolding as required for the proper execution of the work shall be erected. If work can be done
safely with the ladder or jhoola these will be permitted in place of scaffolding.
14.1.2 Cutting
The mortar of the patch, where the existing plaster has cracked, crumbled or sounds hollow when
gently tapped on the surface, shall be removed. The patch shall be cut out to a square or rectangular
shape at position marked on the wall as directed by the Engineer-in-Charge or his authorized
representative. The edges shall be slightly under cut to provide a neat joint.

The masonry joints which become exposed after removal of old plaster shall be raked out to a
minimum depth of 10 mm in the case of brick work and 20 mm in the case of stone work. The raking
shall be carried out uniformly with a raking tool and not with a basuli, and loose mortar dusted off.
The surface shall then be thoroughly washed with water, and kept wet till plastering is commenced.
In case of concrete surfaces, the same shall be thoroughly scrubbed with wire brushes after the
plaster had been cut out and pock marked as described in 13.1.2. The surface shall be washed and
cleaned and kept wet till plastering is commenced.

Mortar of specified mix with the specified sand shall be used. The method of application shall be
as described for single coat plaster work of the specified mix and under Chapter 13. The surface
shall be finished even and flush and matching with the old surrounding plaster. All roundings necessary
at junctions of walls, ceilings etc. shall be carried out in a tidy manner as specified in sub-head 13.0.
All dismantled mortar & rubbish etc. shall be disposed off within 24 hours from its dismantling
promptly as directed by the Engineer-in-Charge.
14.1.5 Protective Measure

Doors, windows, floors, articles of furniture etc. and such other parts of the building shall be
protected from being splashed upon. Splashing and droppings, if any, shall be removed by the
contractor at his own cost and the surface cleaned. Damages, if any, to furniture or fittings and
fixtures shall be recoverable from the contractor.
14.1.6 Curing
Curing shall be done as per plaster work with special reference to the particular type of plaster
mix as described under sub-head ’finishing’.
14.1.7 Finishing
After the plaster is thoroughly cured and dried the surface shall be white washed or colour washed
to suit the existing finishing as required unless specified.

14.1.8 Measurements
Length and breadth shall be measured correct to a cm. The area shall be calculated in square
metre correct to two places of decimal. Patches below 0.05 square metre in area shall not be measured
for payment.
Pre- measurements of the patches to be plastered shall be recorded after the old plaster has
been cut and wall surface prepared.
14.1.9 Rate
The rate includes the cost of all the materials and labour involved in all the operations described
above including lead as described in the item for disposal of old dismantled plaster /material.
14.2 FIXING DOOR, WINDOW OR CLERESTORY WINDOW CHOWKHATS IN EXISTING OPENING
14.2.1 Making Holes
14.2.1.1 In case of door frames without sills, holes 40 mm deep shall be made in the floor for fixing
the lower end of verticals of the frames. For doors with sills, the sill plates shall be partly fixed in the
floor so that they project above the floor to the height as directed by the Engineer-in-Charge.
14.2.1.2 For embedding hold fasts of doors, windows or clerestory windows, the requisite number of
holes at the correct positions shall be cut out in the masonry. The size of the holes shall be such that
the chowkhats with the hold-fasts can be conveniently erected in position. Where necessary, masonry
shall be chipped uniformly to facilitate easy insertion of the frame in the opening.
14.2.1.3 Special care shall be taken when holes are made in load bearing pillars or wall portions
separated by openings to ensure that beams etc. supported by them are properly propped up. In such
portions cutting holes shall be done on one side at a time. The sides of the holes shall be truly parallel
and perpendicular to the plane of the wall. Due care shall be taken, not to disturb the adjoining masonry
and the masonry under the bearings of lintels and arches etc. spanning the opening. The holes shall
then be cleaned of all dust, mortar and brick bats or stone pieces and thoroughly wetted.
14.2.2 Fixing
The sides of chowkhats of door, window or clerestory window abutting against or to be embedded
in masonry shall be painted with two coats of coal tar before being placed in position. The chowkhats
shall than be inserted in position with their hold-fasts bolted tight. The chowkhats shall than be
adjusted to proper line and plumb and secured in position by temporary bracing which shall not be
disturbed or removed until the hold fasts are embedded in the masonry and the concrete block has
set. The concrete to be used for embedding hold- fasts shall be cement concrete 1:3:6 mix (1 cement
: 3 coarse sand : 6 graded stone aggregate 20 mm nominal size).
The minimum size of concrete block in which the hold-fasts will be embedded shall be 30 x 10 x 15
cm for 35 cm long holdfasts. The concrete of the block shall completely fill the hole made in the
masonry for the purpose. The chase cut in the floor shall be cut square and construction joint shall
be provided filled in with cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 graded stone aggregate
20 mm nominal size) and rendered smooth at the top and finished to match the existing type of floor.
14.2.3 Finishing
After the surface surrounding the hold-fasts has sufficiently dried it shall be cleaned of dust etc.
and wetted. It shall then be plastered with cement mortar 1:4 (1 cement : 4 fine sand) flush and
matching with the surrounding plaster work. In case of exposed brick work, stone work, the finishing
shall be done to match the surrounding. Any other portion of the wall opening, if damaged, shall be
repaired in similar way.

After the cement plaster patches have been thoroughly cured and dried, they shall either be
white washed or colour washed as required unless otherwise specified. All malba and debris obtained
from cutting etc. shall be disposed off to the nearest dumping ground promptly as directed by Engineer-
in-Charge.
14.2.4 Measurements
The chowkhats of doors, window and clerestory windows shall be enumerated separately.
14.2.5 Rate
The rate shall apply irrespective of the size of the chowkhat upto a maximum area of opening
3.75 square metres for doors, 2.5 square metres for windows and 1.2 square metres for clerestory
windows. The rate is inclusive of labour and materials involved in all the operations described above,
excluding (a) cost of chowkhats and (b) cost of supplying and fixing the hold-fasts including C.C.
block and bolts.
14.3 FIXING CHOWKHATS IN EXISTING OPENING IN BRICKS / RCC WALL WITH DASH FASTNERS
14.3.1 In case of door frames without sills, holes 40 mm deep shall be made in the floor for fixing the
lower end of verticals of the frames. For doors with sills, the sill plates shall be partly fixed in the floor
so that they project above the floor to the height as directed by the Engineer-in-Charge.
14.3.1.1 For fixing dash fastners /chemical fastners of doors, windows or clerestory windows, the
requisite number of holes at the correct positions shall be in the masonry/RCC wall. The size of
holes shall be such that the fastners can be conveniently placed in position. Where necessary,
masonry shall be chiped uniformly to facilitate easy insertion of the frame in the opening.
14.3.1.2 Special care shall be taken when holes are made in load bearing pillars or wall portions
separated by openings to ensure that beams etc. supported by them are properly propped up. In
such portions cutting holes shall be done on one side at a time. The sides of the holes shall be truly
parallel and perpendicular to the plane of the wall. Due care shall be taken, not to disturb the adjoining
masonry and the masonry under the bearings of the lintels and arches etc. spanning the opening.
The holes shall then be cleaned of all dust, mortar and brick bats or stone pieces and thoroughly
wetted.
14.3.2 Fixing
The sides of chowkhats of door, window or clerestory window abutting against or to be embedded
in masonry shall be painted with two coats of coal tar before being placed in position. The chowkhats
shall then be inserted in position tight. The chowkhats shall then be adjusted to proper line and
plumb and secured in position by temporary bracing which shall not be disturbed or removed until
the fastners are embedded in the masonry /RCC wall.
14.3.3 Finishing
After the surface surrounding the hold-fasts has sufficiently dried it shall be cleaned of dust etc.
and wetted. It shall then be plastered with cement mortar 1:4 (1 cement: 4 fine sand) flush and
matching with the surrounding plaster work. In case of exposed brick work, stone work, the finishing
shall be done to match the surrounding. Any other portion of the wall opening, if damaged, shall be
repaired in similar way.
After the cement plaster patches have been thoroughly cured and have dried, they shall either
be white washed or colour washed as required unless otherwise specified. All malba and debris
obtained from cutting etc. shall be disposed off to the nearest dumping ground.

14.3.4 Measurements
The chowkhats of doors, window and clerestory windows shall be enumerated separately.
14.3.5 Rate
The rate shall apply irrespective of the size of the chowkhat upto a maximum area of opening 3.75 square
metres for doors, 2.5 square metres for windows and 1.2 square metres for clerestory windows. The rate is
inclusive of labour and materials involved in all the operations described above, including cost of dash fastners
chemical fasteners but excluding cost of chowkhat.
14.4 MAKING OPENING IN THE MASONRY CONSTRUCTION AND FIXING CHOWKHATS FOR DOORS,
WINDOWS AND CLERESTORY WINDOWS
14.4.0 Before making opening it is necessary to examine that the wall exclusive of opening is adequate to
take the load coming on the structure. All the structural members supported on the walls which have direct
bearing over the area in which opening is to be made, shall be properly supported with props to relieve the load
from masonry wall till the lintel over the opening is strong enough to take the load. Care should also be taken
not to disturb the adjoining masonry.
All precautions as explained in Chapter 15.0 (Demolition and Dismantling) should be followed in case of
dismantling the external walls. The portion to be dismantled may be clearly marked on both sides of the wall.
Dismantling shall be carried out from top to bottom within the marked area. The sides of the opening shall be
as far as possible, parallel and perpendicular to the plane of wall.
14.4.1 Making Opening

14.4.1.1 The openings for fixing door/window frames shall be to the extent of accommodating the hold fast. The
hold fasts shall be fixed in cement concrete 1:3:6 (1 cement : 3 coarse sand : 6 stone aggregate 20 mm nominal
size) or in masonry as required. Where only opening is to be made in the masonry, the width of the opening shall
be such that the sides of the masonry can be built true to line and plumb and such masonry built shall conform
to the specifications of the particular type of masonry in which the opening is made with particular reference to
size of corner stones etc. In order to get continuity with old masonry, proper key shall be provided. The height of
the opening shall be such that it can accommodate the required depth of the RCC lintel also.
14.4.1.2 The sides of opening in masonry shall be cleaned of all dust, mortar, brick bats/loose stones, chips
etc. and the surface left rough and thoroughly wetted.
14.4.1.3 The lintel shall be invariably cast first in the opening made for the purpose. One side of the shuttering
shall be kept open in the beginning till the concrete is laid. The shuttering shall then be fixed for half of the
opening and concreting completed.
14.4.1.4 Curing of lintel casted shall be done for a minimum period of 7 days.
14.4.1.5 Precast RCC lintel or R.S. Joist may also be used if directed by the Engineer-in-Charge.
14.4.2 Fixing Chowkhats

Fixing of chowkhats shall be done as specified in 14.2.2.
14.4.3 Finishing
14.4.3.1 After the surface of the sides of masonry opening and lintel are sufficiently dry and set, it shall be cleaned
free of dust, loose mortar etc. and wetted thoroughly. It shall then be plastered or pointed as required flush with the
surrounding masonry work. Any other portion of the wall if damaged shall be finished in similar manner.
14.4.3.2 After the cement plaster/pointing has been thoroughly cured and have dried the surface shall be
either white or colour washed/painted as required. The surface of the wall which is spoiled due to splashing of
mortar shall be cleaned forthwith.

14.4.4 Measurements
The openings made for doors, windows, clerestory windows shall be measured correct to cms
and area shall be calculated in square metres correct to two places of decimal.
14.4.5 Rate
The rate shall apply per sqm of opening. The rate is inclusive of labour and material involved in
all the operations described above.
Cost of Chowkhats, cost of CC blocks, cost of supplying the hold-fasts bolts, cost of R.C.C lintel
or R.S. Joist which shall be paid for separately.
14.5 RENEWING FLOATING GLASS PANES WITH PUTTY AND NAILS
14.5.1 Removing Broken Glass Panes

Old putty shall be raked out with hack knife. The brad (small nails without head) and pieces of
broken glass shall be removed from the rebates of the sash bars. The pieces of glass panes as
found useful shall be handed over to the Engineer-in-Charge of the work. No glass shall be inserted
in frames until they have been primed and prepared for painting so that the wood may not draw oil
out of the putty.
14.5.2 Floating Glass Panes

The floating glass panes shall conform to specifications described in IS 14900.
14.5.3 Fixing
The floating glass panes shall be so cut that it fits slightly loose in the frame and as specified in
A&B of IS 14900. A thin layer of Putty conforming to IS 419 shall be prepared by mixing one part of
white lead with three parts of finely powdered chalk and then adding the boiled linseed oil to the
mixture to form a stiff paste and adding varnish to the paste @ 1 litre of varnish to 18 kg. of paste.
The putty so prepared in the form of a stiff paste shall be drawn along the inner edge of the rebate,
for bedding the back of the glass panes. The glass pane shall then be put in position, pressed home
against the thin layer of the putty, and secured in rebate by new brads. The brads shall not be
spaced more than 7.5 cm from each corner and not more than 15 cm apart. The putty shall then be
applied in the rebate uniformly, sloping from the inner edge of the rebate. In doing this care shall be
taken to keep the putty a little within the inner edge of the rebate and surplus putty removed so that
none of it is seen through the glass from the inside. The putty so filled in the rebates shall be levelled
smooth and finished in a straight line. When dried the putty shall be covered with a coat of paint of
approved quality and shade to match the existing finish of joinery work.
The floating glass panes shall be cleaned with methylated spirit. All splashings or droppings of
washing and paints shall be removed. All rubbish and unserviceable materials shall be disposed off
to the dumping ground promptly as per the direction of Engineer-in-Charge.
Thickness and Tolerance of Floating Glass

Thickness Tolerance
4 mm ± 0.3 mm
5 mm ± 0.3 mm
6 mm ± 0.3 mm
Note : Frosted glass panes should be replaced with frosted glass panes. These shall be fixed with
frosted face on the inside.
14.5.4 Measurements
Length and breadth of glass panes shall be measured correct to a cm. The area of the glass
panes as fixed shall be calculated in square metre correct to two places of decimal.

14.5.5 Rate
The rate shall include the cost of labour and materials involved in all the operations described above.
14.6 RENEWING FLOATING GLASS PANES WITH WOODEN FILLETS

14.6.1 Removing Broken Glass Panes
The specifications shall be the same as in para 14.5.1 except that the wooden fillets including nails shall
be taken out carefully.
14.6.2 Glazing
The specifications for glass panes and their fixing shall be the same as per IS 14900. The fillet shall either
be fixed flush or projected uniformly to match with the existing work by means of nails (brads).
The new fillet provided shall be painted or finished otherwise to match with the existing finish of the
joinery work.
The glass panes shall be cleaned with methylated spirit of all sorts of splashing and droppings of wash
and paints.
All rubbish and unserviceable materials shall be disposed off in the dumping ground promptly as per the
direction of Engineer-in-Charge.
14.6.3 Measurements
Length and breadth of glass panes shall be measured correct to a cm. The area of the glass panes as
fixed shall be calculated in square metre correct to two places of decimal. The new wooden fillets fixed shall
be measured in running metres correct to a cm.
14.6.4 Rate
The rates shall include the cost of labour and material involved in all the operations described above
except that the cost of new wooden fillets used in the work and their finishing shall be paid for separately.
14.7 RENEWING FLOATING GLASS PANES AND REFIXING EXISTING WOODEN FILLETS The
specifications shall be same as described in 14.6 above.
14.8 PROVIDING NEW WOODEN FILLETS

14.8.1 The fillets shall be of wood, as specified in the item of work, these shall be cut and planed smooth to
the required shape and dimensions.
14.8.2 Fixing
The specifications for glass panes and their fixing shall be the same as given in 9.6.4.6. The fillet shall
either be fixed flush or projected uniformly to match the existing work.
The fillet shall be painted or finished otherwise to match with the existing finish of the joinery work.
The glass panes shall be cleaned with methylated spirit of all sorts of splashing and dropping of wash and
paints.
14.8.3 Measurements
The fillets shall be measured in running metres. The lengths shall be measured correct to a cm.
14.8.4 Rate
The rate shall also include the cost of removal of worn out fillets, when these are met with in old work. The rate
shall vary according to the class of wood used.

14.9 RENEWAL OF OLD PUTTY OF GLASS PANES
14.9.1 The old putty shall be removed as specified in 14.5.1 and new putty fixed as specified in 14.5.3.
14.9.2 Measurements
The work shall be measured in running metres. The length along the rebate shall be measured correct
to a cm.
14.9.3 Rate
The rate shall include the cost of labour and materials involved in all the operations described above.
14.10 REFIXING OLD GLASS PANES WITH PUTTY AND NAILS
14.10.1 Specification same as described in 14.5 above. Except for the glass panes, old glass panes will be
used for which nothing extra will be paid.
14.11 FIXING OLD GLASS PANES WITH WOODEN FILLETS
14.11.1 Specifications same as described in para no. 14.6 above except for the glass panes. Old glass panes
will be used for which nothing extra shall be paid.
14.12 FIXING FAN CLAMPS IN EXISTING R.C.C. SLABS
14.12.1 The fan clamps to be fixed in an existing R.C.C. slab shall be of type shown in Fig. 14.1. These shall
be made of 16 mm dia M.S. bar.
14.12.2 Fixing
A 15 x 7.5 cm size chase shall be cut from the ceiling to expose the reinforcement and upto 2.5 cm clear round
the reinforcement bar as directed. This shall be done without any damage to adjoining portion of the ceiling.
The two arms at the ends of the clamps shall be passed through the space over the reinforcement bar
from the bottom of the slab. Then the two arms shall be bent down about 1.5 cm by means of a crow bar. The
clamp shall be held in position and chase in the ceiling filled with cement concrete 1:2:4 (1 cement : 2 coarse
sand : 4 graded stone aggregate 20 mm nominal size). The ceiling shall then be finished to match the existing
surface and properly cured.
The exposed portion of the clamp shall be given two or more coats of paint including one priming coat of
shade as directed by the Engineer-in-Charge.
14.12.3 Measurements and Rate

Clamps shall be counted in numbers. The rate per fan clamp shall include the cost of labour and materials
involved in all the operations described above. The rate shall apply irrespective of the thickness of the slab.
14.13 REGRADING OF MUD PHUSKA TERRACING
14.13.1 Dismantling
The specified area of roof as directed by the Engineer-in-Charge shall be dismantled carefully so that the
minimum of tiles or bricks are damaged. The serviceable tiles or bricks shall be cleaned and stacked on
places as directed by the Engineer-in-Charge, or on the parapet wall if convenient and safe or otherwise
carried to ground and stacked as directed by the Engineer-in-Charge for which nothing extra shall be paid.
All unserviceable tiles and debris shall be disposed off to the dumping ground as directed by the Engineer-
in-Charge. Suitable earth shall be stacked separately for reuse.

14.13.2 Laying
Mud phuska shall be removed, cleaned of all foreign matter and brought to the ground. After
approval of the Engineer-in-Charge it shall then be reduced to fine powder and then mixed with
additional soil for regrading and additional fibrous reinforcing materials such as chopped straw or
fresh bhusa at the rate of 8 kg/cum of mud mortar shall be mixed with old earth. The choppings used
shall not be more than 20 mm in length. A pit shall be dug where the mixture shall be added and
allowed to mature for a period of not less than 7 days. During this period the mixture shall be worked
up at interval with feet and spades so as to get pugged into homogeneous mass free from lumps and
clods. The consistency of the mortar shall be adjusted by taking it in a trowel and observing how it
slides off the face of the trowel. The mortar shall readily slide off, but at the same time shall be so wet
as to part into large drops before falling.
14.13.3 Leeping Plaster

Shall be prepared by mixing soil which is free from coarse sand with approximately equal volume of
cow dung and adding the required quantity of water. The mixture shall work to a homogeneous mass. The
quantity of gobar used in gobri leeping shall not be less than 0.03 cum per 100 sqm of plaster area.
14.13.4 Laying Tile Bricks and Grouting

The specifications shall be as described in 12.11.4 except that new tile as necessary to replace
the broken tiles shall be used. Half or cut brick tiles shall not be used except where necessary to
complete the bond. New work shall be finished in level with surrounding surface.
14.13.5 Curing and Measurements

Shall be as specified in 12.11.5 and 12.11.6.
14.13.6 Rate
above except for new tiles or bricks which shall be paid for separately.
14.14 REPLACING RED OR WHITE SAND STONE SLABS IN ROOFING
14.14.1 Dismantling Roof

The general specifications given in 15.1 shall apply. The cracked or decayed stone slabs as
marked by the representative of the Engineer-in-Charge shall be removed after dismantling the tile
covering with mud phuska over it if any, or other type of covering over the stone slabs.
Mud phuska terracing with tile brick covering shall be dismantled as per 14.13.1 over the specified
cracked or decayed tiles to an area extending 15 cm on all sides of stone slabs. This area may be
increased by the Engineer-in-Charge, if found necessary. Stone slabs shall then be dismantled and
carried down and stacked properly.
In case the stone slabs are not covered at top with mud phuska or lime terracing, the decayed or
cracked stone slabs shall be dismantled and carried down or lowered with ropes and stacked properly.
14.14.2 Relaying of Stone Slab Roofing

Before placing the stone slab the condition of the existing wooden battens shall be checked by
suitable methods and replaced if required by Engineer-in-Charge. The upper surface of the wooden
battens and beams supporting the stone slab, shall be painted with two coats of coal tar if not
already treated and with one coat of coal tar if originally treated.
The specifications for stone slabs, laying, finishing and curing, shall be as described under 12.15.
14.14.3 Relaying of Mud Phuska with Tile

The specifications shall be as described in 14.13.2 to 14.13.4 and shall be paid for separately.

14.14.4 Curing and Measurements
Shall be done as described in 12.11.5 and 12.11.6.
14.14.5 All unserviceable material shall be disposed off to the dumping ground as directed by the
Engineer-in-Charge.
14.14.6 Rate
The rate shall include the cost of materials and labour involved in all the operations described
above, except the cost of wooden battens which shall be paid for separately.
14.15 RENEWING WOODEN BATTENS /BEAMS IN ROOFS

14.15.1 Dismantling Wooden Battens / Beams
Dismantling shall be done as described in para 15.1 of dismantling and demolishing. Proper
scaffolding shall be erected and got inspected by Engineer-in -Charge. Propping and bracing as
directed should be done adequately and members required to be dismantled should be removed
carefully including nails/bolts etc. and dismantling of masonry wall. The dismantled members should
not be thrown or dropped but lowered with ropes carefully and stacked properly.
14.15.2 Relaying of Wooden Battens

The wooden battens/beams of required section and size should be placed at proper interval and
surface of the wooden batten/beams shall be painted with oil type wood preservative of approved
brand and manufacture and as per the direction of Engineer-in-Charge.
14.15.3 All serviceable material shall be stacked properly and all the unserviceable material shall be
deposited with the Engineer-in-Charge.
14.15.4 Measurement
The work shall be measured in cubic meters. The length, breadth and depth shall be measured
correct to a cm.
14.15.5 Rate
The rate shall include the cost of materials and labour involved in the operations described above.
14.16 PANELLED GLAZED OR PANELLED AND GLAZED SHUTTERS

14.16.0 Pannelled or glazed shutters for doors, windows, ventilators and cupboards shall be constructed
in the form of timber frame work of stiles and rails with panel inserts of timber, plywood, block board,
veneered particle board, fibre board wire gauze or sheet glass. The shutters may be single or
multipanelled, as shown in the drawings or as directed by the Engineer-in-Charge. Timber for frame
work, material for panel inserts and thickness of shutters shall be as specified. All members of the
shutters shall be straight without any warp or bow and shall have smooth well planed face at right
angles to each other.
Any warp or bow shall not exceed 1.5 mm. The right angle for the shutter shall be checked by
measuring the diagonals and the difference between the two diagonals should not be more than ± 3 mm.
14.16.1 Frame Work
14.16.1.1 Timber for stiles and rails shall be of the same species and shall be sawn in the directions of
grains. Sawing shall be truly straight and square. The timber shall be planed smooth and accurate to
the required dimensions. The stiles and rails shall be joined to each other by plain or haunched
mortise and tenon joints and the rails shall be inserted 25 mm short of the width of the stiles. The
bottom rails shall have double tenon joints and for other rails single tenon joints shall be provided. The
lock rails of door shutter shall have its centre line at a height of 800 mm from the bottom of the shutters
unless otherwise specified. The thickness of each tenon shall be approximately one- third the finished
thickness of the members and the width of each tenon shall not exceed three times its thickness.

14.16.1.2 Gluing of Joints : The contact surfaces of tenon and mortise shall be treated, before putting
together, with bulk type synthetic resin adhesive conforming to IS 851 suitable for construction in
wood or synthetic resin adhesive (Phenolic and aminoplastic) conforming to IS 848 or polyvinyl
acetate dispersion based adhesive conforming to IS 4835 and pinned with 10 mm dia hardwood
dowels or bamboopins or star shapped metal pins; after the frames are put together and pressed in
position by means of press.
14.16.1.3 Stiles and bottom rail shall be made out of one piece of timber only. Intermediate rail
exceeding 200 mm in width may be out of one or more pieces of timber. The width of each piece shall
be not less than 75 mm. Where more than one piece of timber is used for rails, they shall be joined
with a continuous tongued and grooved joint glued together and reinforced with metal dowels at
regular intervals not exceeding 200 mm.
TABLE 14.1
Dimensions of Components of Frame Work
Sl. No. Description Width Thickness
Mm mm
A. DOOR SHUTTERS
(a) Stile, top and freeze rail 100 35 or 40
(b) Lock rail 150 35 or 40
(c) Bottom rail 200 35 or 40
(d) Muntin 100 35 or 40
(e) Glazing bar 40 35 or 40
B. WINDOW, VENTILATOR & CUPBOARD SHUTTERS

(a) Stile, top and freeze rail 80 20, 25 or 30
(b) Bottom rail 80 20, 25 or 30
(c) Muntin 60 20, 25 or 30
(d) Glazing bar 40 20, 25 or 30
14.16.2 Muntin and glazing bars where required shall be stubtenoned to the maximum depth which
the size of the member would permit or to a depth of 25 mm whichever is less. Unless otherwise
specifed the finished dimensions of the components of frame work of shutters shall be as given in
Table 14.1. The tolerance on width of styles and rail shall be ± 3 mm. The tolerance in thickness will
be ± 1 mm. The thickness of all components of frame work shall be the same as the thickness of the
shutter. Tolerance on over all dimensions of the shutter shall be ± 3 mm.
14.16.3 Rebating
The shutters shall be single-leaf or double leaved as shown in the drawings or as directed by the
Engineer-in-Charge. In case of double leaved shutters, the meeting of the stiles shall be rebated by
one-third the thickness of the shutter. The rebating shall be either splayed or square type as shown
in Fig. 14.2.
14.16.4 Panelling
The panel inserts shall be either framed into the grooves or housed in the rebate of stiles and rails.
Timber, plywood, hard board and particle board panels shall be fixed only with grooves. The depth of
the groove shall be 12 mm and its width shall accommodate the panel inserts such that the faces are
closely fitted to the sides of the groove. Panel inserts shall be framed into the grooves of stiles and rails

to the full depth of the groove leaving on space of 1.5 mm. Width and depth of the rebate shall be equal to half the
thickness of stiles and rails. Glass panels, asbestos panels wire gauze panels and panel inserts of cupboard
shutters shall be housed in the rebates of stiles and rails.
14.16.4.1 Timber Panels : Timber panels shall be preferably made of timber of large width; the minimum
width and thickness of the panel shall be 150 mm, and 15 mm respectively. When made from more than one
piece, the pieces shall be jointed with a continuous tongued and grooved joint glued together and reinforced
with headless nails at regular intervals not exceeding 100 mm. Depth and thickness of such joint shall be
equal to one- third of thickness of panel. The panels shall be designed such that no single panel exceeds 0.5
square metre in area. The grains of timber panels shall run along the longer dimensions of the panels. All
panels shall be of the same species of timber unless otherwise specified.
14.6.4.2 Plywood Panels : Plywood boards used for panelling of shutters shall be BWP type or grade as
specified in 9.2.2. Each panels shall be a single piece of thickness, 9 mm for two or more panel construction
and 12 mm for single panel construction unless otherwise specified.
14.16.4.3 Block Board Panels : Block board used for panelling of shutters shall be Grade I (Exterior Grade)
bonded with BWP Type Synthetic resin adhesives as specified in 9.2.2. Each panel shall be a single piece of
thickness 12 mm unless otherwise specified.
14.16.4.4 Veneered Particle Board Panels : Veneered Particle board used for panelling of shutters shall be
Exterior Grade bonded with BWP type synthetic resin adhesive as specified in 9.2.4.2. Each panel shall be a
single piece of thickness 12 mm unless otherwise specified.
14.16.4.5 Fibre Board Panels : Fibre board used for panelling of shutters shall be Exterior Grade bonded with
BWP type synthetic resin adhesive as specified in 9.2.8.2. Each fibre board panel shall be a single piece of
thickness 10 mm unless otherwise specified.
14. 16.4.6 Wire Gauze Panels : Wire Gauze used for panelling of shutters shall be woven with 0.63 mm dia
galvanised mild steel wire to form average aperture size of 1.40 mm as specified in 9.2.10. Wire gauze shall be
securely housed into the rebates of stiles and rails by giving right angles bend turned back and fixed by means
of suitable staples at intervals of 75 mm and over this wooden beading shall be fixed. The space between the
rebate and the beading shall be fixed with putty to give a neat finish. Each wire gauze panel shall be a single
piece, and the panels shall be so designed that no single panels exceeds 0.5 sqm in area. However, care shall
be taken to prevent sagging of wire gauge, of panel by providing and fixing 20 x 20 mm square or equivalent
beading to the external face in the required patterns as decided by the Engineer-in-Charge.
14.16.4.7 Glass Panels : Glass panelling (Glazing) shall be done with float sheet glass as per IS 14900. Glazing
in the shutters of doors, windows and ventilators of bath, WC and Lavatories shall be provided with frosted glass
the weight of which shall be not less than 10 kg/sqm. Frosted glass panes shall be fixed with frosted face on the
inside. Glass panels shall be fixed by providing a thin layer of putty conforming to IS 419 applied between glass
pane and all along the length of the rebate and also between glass panes and wooden beading.
14.16.4.8 Putty can be prepared by mixing one part of white lead with three parts of finely powdered chalk and
then adding boiled linseed oil to the mixture to form a stiff paste and adding varnish to the paste at the rate of 1
litre of varnish to 18 kg of paste. Fixing of glass panes without beading shall not be permitted. Glazing shall be
done after the shutters have been primed and prepared for painting, so that wood may not draw oil out of putty.
14.16.4.9 Finish : Panels of shutters shall be flat and well sanded to a smooth and level surface.
14.16.5 Beading
Beadings in panelled shutter shall be provided where specified in architectural drawings or directed by the
Engineer-in -Charge. Each length of beading shall be single piece. Joints at the corners shall be mitred and
exposed edges shall be rounded. Beading shall be fixed with headless nails at 75 mm intervals. For external
shutters, the beading shall be fixed on the outside face.

14.16.6 Machine/Factory made Shutters
Machine made shutters, where specified, shall be procured from an approved factory. For machine
made shutters, operations like sawing, planning, making tongue and tenons, cutting grooves, mortises
and rebates, drilling holes and pressing of joints shall be done by suitable machines. Machines
made shutters shall be brought to the site fully assembled but without any priming coat. Panel inserts
of sheet glass and wire gauze may, however, be fixed at site.
14.16.7 Fixing of Shutters

For side hung shutters of height upto 1.2 m, each leaf shall be hung on two hinges at quarter
points and for shutter of height more than 1.2 m, each leaf shall be hung on three hinges one at the
centre and the other two at 200 mm from the top and bottom of the shutters. Top hung and bottom
hung shutters shall be hung on two hinges fixed at quarter points of top rail or bottom rail. Centre
hung shutter shall be suspended on a suitable pivot in the centre of the frame. Size and type of
hinges and pivots be as specified. Flap of hinges shall be neatly counter sunk into the recesses cut
to the exact dimensions of flap. Screws for fixing the hinges shall be screwed in with screw driver and
not hammered in. Unless otherwise specified, shutters of height more than 1.2 m shall be hung on
butt hinges of size 100 mm and for all other shutters of lesser height butt hinges of size 75 mm shall
be used. For shutter of more than 40 mm thickness butt hinges of size 125 × 90 × 4 mm shall be
used. Continuous (piano) hinges shall be used for fixing cup-board shutters where specified.
14.16.8 Fittings
Fittings shall be provided as per schedule of fittings decided by Engineer-in- Charge. Appendix H
(P-361/SH 9.0) gives for guidance the schedule of fittings and screws usually provided. Cost of
providing and fixing shutter shall include cost of hinges and necessary screws for fixing the same. All
other fittings shall be paid for separately. The fittings shall conform to specifications laid down in
9.6.8. Where the fittings are stipulated to be supplied by the department free of cost, screws for
fixing these fittings shall be provided by contractor and nothing extra shall be paid for the same.
14.16.9 Wooden Cleats and Blocks

Wooden cleats and blocks shall be fixed to doors and windows as directed by Engineer-in-Charge,
as per size and shape approved by him. These are included in the cost of providing and fixing the
shutters.
Framework and panelling shall be measured separately.
14.16.10.1 Frame Work of Shutters : The overall length and width of the framework of the shutters
shall be measured nearest to a cm in fixed position (overlaps not to be measured in case of double
leaved shutters) and the area calculated in square metres correct to two places of decimeter. No
deduction shall be made to form panel openings or louvers. No extra payments shall be made for
shape, joints and labour involved in all operations described above.
14.16.10.2. For panelling of each type or for glazed panel length and width of opening for panels
inserts or glazed panels shall be measured correct to a cm before fixing the beading and the area
shall be calculated to the nearest 0.01 sq.m. The portions of the panel inserts or glazed panel inside
the grooves or rebates shall not be measured for payment.
14.16.11 Rate
Rate includes the cost of materials and labour involved in all the operations described above.
The frame work and panelling of each type or glazed panels shall be paid separately. The rate for
frame work includes the cost of butt hinges and necessary screws as specified in 9.6.7. However,
extra shall be paid for providing moulded beading where specified. Nothing extra shall be paid for
plain beading as stated in 9.6.5 when specified in drawing.

14.17 TRELLIS (JAFFRI) WORK
14.17.0 Specified timber shall be sawn in the direction of the grains. Sawing shall be truly straight
and square. The timber shall be plained smooth and accurate to the full dimensions, rebates,
roundings, and mouldings as shown in the drawings made, before assembly. Patching or plugging of
any kind shall not be permitted except as provided.
14.17.1 Plain Trellis (Jaffri)

This shall consist of wooden strips or laths 35 x 10 mm section unless otherwise specified plained
and nailed together at every alternate crossing. The strips shall cross each other at right angle and
shall be spaced 35 mm apart, so as to form 35 × 35 mm square opening or as shown in the drawing.
These shall be fixed with nails to the frame. To cover the ends of strips, 50 × l2 mm beading shall be
fixed to the frame with screws. The finished work with a tolerance of ± 1 mm may be accepted.
14.17.2 Trellis (Jaffri) Doors and Windows Shutters

Shutter frame of specified timber shall consist of two stiles and top, lock and bottom rails, each of
section 75 × 35 mm unless otherwise specified. The stiles and rails shall be properly mortised and
tenoned. The tenons shall pass through the stiles for at least 3/4th of the width of the stile. Shutter
frame shall be assembled and passed by the Engineer-in-Charge before jointing. The joints shall be
pressed and secured by bamboo pins of about 6 mm diameter. To this frame, plain trellis (Jaffri) work
as described in 9.11.1 shall be fixed as shown in the drawings or as directed by the Engineer-in-
Charge. Fixing, fittings, wooden cleats and blocks shall be provided as specified under 9.6.
Width and height of plain trellis work and trellis shutters shall be measured overall correct to a
cm. The area shall be calculated in square metres nearest to two places of decimal. In case of
shutters, the measurement shall be as specified in 9.11.2.
14.17.4 Rate
It includes the cost of materials and labour required in all the operations described above.
14.18 FITTINGS
14.18.0 Fitting shall be of mild steel brass, aluminium or as specified. Some mild steel fittings may
have components of cast iron. These shall be well made, reasonably smooth, and free from sharp
edges and corners, flaws and other defects. Screw holes shall be counter sunk to suit the head of
specified wood screws. These shall be of the following types according to the material used.
(a) Mild Steel Fittings

These shall be bright satin finish black stone enamelled or copper oxidised (black finish),
nickel chromium plated or as specified.
(b) Brass Fittings

These shall be finished bright satin finish or nickel chromium plated or copper oxidised or as
specified.
(c) Aluminium Fittings

These shall be anodised to natural matt finish or dyed anodic coating not less than grade
AC 10 of IS 1868.
The fittings generally used for different type of doors and windows are indicated in Appendix H
(P-361/SH 9.0) attached. The fittings to be actually provided in a particular work shall, however, be
decided by the Engineer-in-Charge.

Screws used for fittings shall be of the same metal, and finish as the fittings. However, chromium plated
brass screws or stainless steel screws shall be used for fixing aluminium fittings. These shall be of the size
as indicated in respective figures.
Fittings shall be fixed in proper position as shown in the drawings or as directed by the Engineer-in-
Charge. These shall be truly vertical or horizontal as the case may be. Screws shall be driven home with
screw driver and not hammered in. Recesses shall be cut to the exact size and depth for the counter sunking
of hinges.
14.18.1 Butt Hinges

(a) Cast brass butt hinges light/ordinary or heavy.
14.18.1.1 Cast Brass Butt Hinges : These shall be light/ordinary or heavy as specified. These shall be well
made and shall be free from flaws and defects of all kinds. These shall be finished bright or chromium plated
or oxidised or as specified. These shall generally conform to IS 205.
Hinge Pin : Hinge pin shall be made of brass or of phosphor bronze. The hinge pins shall be firmly rivetted and
shall be properly finished. The movement of the hinge pin shall be free, easy and square and shall not have
any play or shake.
Knuckles : The number of knuckles in each hinge shall not be less than five. The number of knuckles in case
of sizes less than 40 mm shall be three. The sides of the knuckles shall be straight and at right angle to the
flap. The movement of the hinge pin shall be free and easy and working shall not have any play or shake.
Screw Holes : The screw holes shall be clean and counter sunk and of the specified size for different types
and size of hinges. The size of the holes shall be such that when it is counter sunk it shall be able to
accommodate the full depth of counter sunk head of wood screw specified.
14.18.1.2 Sampling and Criteria for Conformity : The number of butt hinges to be selected from a lot shall
depend on the size of lot and shall be in accordance with Table 10. Butt hinges for testing shall be taken at
random from at least 10 per cent of the package subject to a minimum of three, equal number of hinges being
selected from each package. All butt hinges selected from the lot shall be checked for dimensional and
tolerance requirements. Defects in manufacture and finish shall also be checked. A lot shall be considered
conforming to the requirements of this specification if the number of defective hinges among those tested
does not exceed the corresponding number given in Table 14.2.
TABLE 14.2
Permissible No. of defective
Lot size Sample size hinges
Upto 200 15 0
201 to 300 20 1
301 to 500 30 2
501 to 800 40 2
801 and above 55 3
Note: Any hinge which fails to satisfy the requirements of any one or more of the characteristics
shall be considered as defective hinge.
14.18.2 Spring Hinges : (Single or double acting)
14.18.2.1 These shall be single acting when the shutter is to open on one side only or double acting
when the shutter opens on both sides. These shall be made of M.S. or brass as specified, and shall
generally conform to IS 453.

Hinges shall work smoothly and shall hold the door shutter truly vertical in closed position. Each
double-acting spring hinge shall withstand the following tests which shall be carried out after fixing it
to a swing door in the normal manner.
(a) When the door is pushed through 90° and released 2000 times on each side in quick
succession the hinge shall show no sign of damage or any appreciable deterioration of the
components during or on completion of the test.
(b) The door shall require a force of 2.0 ± 0.5 kg for 100 mm hinges and 3.0 ± 0.5 kg for 125 mm
and 150 mm hinges at a distance of 4.5 cm from the hinge pin to move the door through 90º.
The size of spring hinge shall be taken as the length of the plate.
14.18.2.2 These shall be of the following type :
(a) Mild Steel : The cylindrical casing shall be made either from M.S. sheet of 1.60 mm thickness,
lap jointed and brazed, welded and rivetted, or from solid drawn tube of thickness, pressed to
from the two casing. It shall be stove enamelled black or copper oxidized or as specified.
(b) Cast Brass : The cylindrical casing shall be made either from brass sheet of 1.60 mm thickness,
lap jointed and brazed, or from solid drawn brass tube of not less than 1.60 mm thickness. It
shall be satin, bright nickle — plated or copper oxidized or as specified.
14.18.2.3 Sampling : The number of spring hinges shall be selected from the lot and this number
shall depend on the size of the lot and shall be in accordance with Table 14.3.
TABLE 14.3
Lot size Sample size Permissible No. of defective spring
hinges
1 to 25 3 0
26 to 50 6 0
51 to 100 12 0
101 to 200 15 0
201 to 300 20 1
301 to 500 30 2
501 to 800 40 2
801 and above 55 3
14.18.3 Flush Bolts (Fig. 14.3)
14.18.3.1 These should generally conform to IS 5187. These shall be of cast brass, cast aluminium
alloy or extruded aluminium alloy as specified. Only one material shall be used in the manufacture of
all the components of flush bolts except spring which shall be of phosphor bronze or steel strip.
When the rod is completely in its maximum bolting position it shall be retained in that position by
the spring. The length of the bolt shall be such that, when the bolt is pulled down, the top of the bolt
shall be flush with the top of the lip face. The top of the bolt shall be given a taper of 45° to enable
easy pull or push.
14.18.3.2 Brass flush bolts shall be satin or bright polished. Alternatively they may be nickel or chromium
plated as specified in IS 4827 or copper oxidised in accordance with IS 1378. Aluminium flush bolts
shall be anodised and the quality of the anodised finish shall not be less than grade AC 15 of IS 1868.

Note : The working of flush bolts is found satisfactory only in case of shutters made of high quality
timber like teakwood properly seasoned and when there is no warping due to changes in
weather Brass flush bolts which give a more satisfactory performance are costly and uses
scarce materials. Hence use of flush bolts is to be discouraged.
14.18.4 Floor Door Stopper (Fig. 14.4)
14.18.4.1 The floor door stopper shall conform to IS 1823. This shall be made of cast brass of overall
size as specified and shall have rubber cushion. The shape and pattern of stopper shall be approved
by the Engineer-in-Charge. It shall be of brass finished bright, chromium plated or oxidised or as
specified. The size of floor stopper shall be determined by the length of its plate. It shall be well made
and shall have four counter sunk holes for fixing the door stoppers to the floor by means of wood
screws. The body or housing of the door stopper shall be cast in one piece and it shall be fixed to the
cover plate by means of brass or mild steel screws and cover plate shall be of casting or of sheet metal.
The spring shall be fixed firmly to the pin. Tongue which would be pressed while closing or opening of
the door shall be connected to the lower part by means of copper pin. On the extreme end a rubber
piece shall be attached to absorb shock. All parts of the door stopper shall be of good workmanship
and finish, burrs and sharp edges removed. It shall be free from surface and casting defects. Aluminium
stopper shall be anodised and anodic film shall not be less than grade AC-10 of IS 1868.
14.18.4.2 Sampling and Criteria for Conformity : It shall be same as specified in 9.21.1.4.
TABLE 14.4
Requirements for Rubber
Particulars Requirements Testing procedure
Relative density Max 1.3 IS 3400 (Part IX)
Hardness 60 ± 5 IS 3400 (Part II)
Change in initial hardness ageing for 24 +5 IS 3400 (Part II)
hours at 100° ± 1° C
14.18.5 Hanging Rubber Door Stopper
14.18.5.1 These shall be of cast brass, finished bright, chromium plated or as specified. Aluminium
stopper shall be anodised and the anodic coating shall not be less than grade AC-10 of IS:1868. The
size and pattern of the door stopper shall be approved by the Engineer-in-Charge. The size shall be
determined by its length.
14.18.6 Casement Brass Stays (Straight Peg Type) (Fig. 14.5)
14.18.6.1 These shall be made of mild steel, cast brass, aluminium (extruded section) or plastic
(Polypropylene) as specified. Mild steel casement stays shall be a copper oxidised(black finish) or as
specified. Cast brass stays shall be finished bright or chromium plated or as specified. Aluminium
stays shall be anodised and the anodic coating shall not be less than grade AC-10 of IS 1868.
Aluminium and M.S. stays shall be made from channel section. The stays shall not weigh less than
that indicated below :
200 mm 0.24 kg each
250 mm 0.28 kg each
300 mm 0.33 kg each
14.18.6.2 The shape and pattern of the stays shall be approved by the Engineer-in-Charge. The
size of stays shall be determined by its length as shown in the plate. The plastic (Polypropylene)
stays shall conform to IS 6318.

14.18.7 Fan Light Pivots
14.18.7.1 These shall generally conform to IS 1837. These shall be of mild steel or cast brass or
Aluminium or as specified. The brass, fan light pivots shall be finished bright, chromium plated or as
specified. M.S. fan light pivot shall be copper oxidized (black finish) or as specified. The base and
socket plate of M.S. fan light pivots shall be made from minimum 3.0 mm M.S. sheet and the pivot
shall be of round M.S. bar of minimum 10 mm diameter projecting out by minimum 12 mm length and
firmly rivetted to the base plate.
14.18.7.2. The base and socket plate of cast brass fan light pivots shall be made from minimum 3.0
mm thick brass plate and the projected pivot shall not be less than 12 mm diameter and 12 mm
length, cast in single piece with the base plate.
14.19 Clause shifted to Sub Head 13 (Finishing) as clause no. 13.14
14.23 PAINTING READY MIXED PAINT OVER G.S. SHEETS

14.23.0 Ready mixed paint, suitable for painting over G.S. sheets, of approved brand and manufacture
and of the required shade shall be used. New or weathered G.S. sheets shall be painted with a
priming coat of one coat of redoxide zinc chromate paint. Primer shall be applied before fixing sheets
in place.

14.23.1.1 Painting New Surface : The painting of new G.S. sheets shall not usually be done till the
sheets have weathered for about a year. When new sheets are to be painted before they have weathered
they shall be treated with a mordant solution prepared by mixing 38 gm of copper acetate in a litre of
soft water or 13 gm hydrochloric acid in a solution of 13 gm each of copper chloride, copper nitrate and
ammonium chloride dissolved in a litre of soft water. This quantity of solution is sufficient for about 235
sqm. to 280 sqm of area and is applied for ensuring proper adhesion of paint. The painting with the
mordant solution will be paid for separately.
Before painting on new or weathered G.S. sheets, rust patches shall be completely cleaned with
coarse emery paper and brush. All grease marks shall also be removed and the surface washed and
dried and rusted surface shall be touched with readymixed paint of red lead.
14.23.1.2 Painting Old Surface : If the old paint is firm and sound, it shall be cleaned of grease,
smoke etc. The surface shall then be rubbed down with sand paper and dusted. Rusty patches shall
be cleaned up and touched with red lead.
If the old paint is blistered and flaked, it shall be completely removed as described in 13.41. Such
removal shall be paid for separately and painting shall be treated as on new work.
14.23.2 Application
The number of coats to be applied shall be as in the description of item. In the case of C.G.S.
sheets, the crowns of the corrugations shall be painted first and when these get dried the general
coat shall be given to ensure uniform finish over the entire surface without the crowns showing signs
of thinning.
The second or additional coats shall be applied when the previous coat has dried.

14.23.3 The specifications described in 13.23 shall hold good so far as they are applicable.
14.27 PAINTING WITH ENAMEL PAINT

14.27.1 Enamel Paint (conforming to IS 2933) of approved brand and manufacture and of the required colour
shall be used.
For the under coat, the paint of same quality but of shade to suit that of the top coat shall be used.
14.27.2 Preparation of surface and application shall be as specified under 13.32 for painting on new surfaces
or old surfaces, as the case may be.
14.31 VARNISHING
14.31.0 Ordinary copal varnish or superior quality spray varnish shall be used. The work includes sizing of
transparent wood filler.
14.31.1 Varnish (conforming to IS 347) for the finishing and undercoats shall be of the approved manufacturer.
14.31.2 Varnishing on New Surfaces

14.31.2.1 Preparation of Surface : New wood work to be varnished shall have been finished smooth with a
carpenter’s plane. Knots shall be cut to a slight depth. Cracks and holes shall be cleaned of dust. The knots,
cracks etc. shall then be filled in with wood putty made as follows:
On a piece of wood say 20 x 15 cm face and on the side where cross grains appear, a small quantity of
glue size shall be poured and the surface scraped with the edge of a fine carpenter’s chisel. Very fine wood
powder shall be mixed with the glue and the stiff paste thus formed shall be used for the filling.
The fillings when dry shall be rubbed down with a carpenter’s file and then the entire surface shall be
rubbed down perfectly smooth with medium grained and fine sand papers and wiped with dry clean cloth so
that it presents uniform appearance. In no case shall sand papers be rubbed across the grains, as in this
case even the finest marks will be visible when the varnishing is applied.
14.31.2.2 Sizing or Transparent Wood Filler Coat : The surface shall then be treated with either glue sizing
or with transparent wood filler coat as stipulated in the description of item.
(a) Sizing : When sizing is stipulated, an application of thin clean size shall be applied hot on the
surface. When dry, the surface shall be rubbed down smooth with sand paper and cleaned. It shall
then be given another application of glue size nearly cold. The sized wood work shall again be rubbed
down smoothly with fine sand paper and cleaned. The surface shall be perfectly dry and all dust shall
be removed not only from the surface but also from the edges and joints before varnishing is commenced.
If the wood work is to be stained, the staining colour shall be mixed with the second coat of the size
which must be applied evenly and quickly keeping the colour on the flow.

Any joining up with work already dry will show badly. The object of application of the glue size is to
seal the pores in wood to prevent absorption of the oil in the varnish.
Glue sizing is inadvisable on floors, table tops and other horizontal surfaces likely to carry wet household
untensils which are likely to disturb the size coatings and thus expose bare wood. Where glue sizing
is omitted to be done the rate for the work shall be suitably reduced.
(b) Transparent Wood Filler Coat : Where instead of glue sizing, transparent wood filler application is
stipulated in the item, then the surface prepared as described in 13.37.2.1 shall be given as application
of the filler with brush or rag in such a way that the filler fills up all the pores and indentations and levels
up the surface. It shall be allowed to dry for 24 hours. Then it shall be cut and rubbed with emery paper
so that the surface of the wood is laid bare, with the filler only in the pores and crevices of the wood.
14.31.2.3 Application of Varnish : The number of coats to be applied shall be as stipulated in the description
of the item.
The undercoat shall be with a flatting varnish. This dries hard and brittle and when cut and rubbed down to
produce a smooth surface enhances the gloss of the finishing varnish. The top coat shall be given with
stipulated brand of finishing varnish.
The varnish shall be applied liberally with a full brush and spread evenly with short light strokes to avoid
frothing. If the work is vertical the varnish shall be crossed and recrossed and then laid off, latter being finished
on the upstrokes so that varnish, as it sets, flows down and eliminates brush marks, the above process will
constitute one coat. If the surface is horizontal, varnish shall be worked in every direction, with light quick
strokes and finish in one definite direction so that it will set without showing brush marks, in handling and
applying varnish care should be taken to avoid forming froth or air bubbles. Brushes and containers shall be
kept scrupulously clean.
Rubbing down and flatting the surface shall be done after each coat except the final coat with fine sand paper.
The work shall be allowed to dry away from droughts and damp air. The finished surface shall then present
a uniform appearance and fine glossy surface free from streaks, blister etc.
Any varnish left over in the small container shall not be poured back into the stock tin, as it will render the
latter unite unfit for use.
Special fine haired varnishing brushes shall be used and not ordinary paint brushes. Brushes shall be well
worn and perfectly clean.
14.31.3 Varnishing on Old Surface

14.31.3.1 Preparation of Surface : If the old varnished surface is firm and sound it shall be cleaned of grease
and dirt with turpentine and then rubbed with wet sand paper until the surface is clean and smooth. It shall be
dried and wiped clean with a soft cloth. Knots, holes and cracks shall be stopped as specified in 13.37.3. The
entire surface shall then be rubbed down smooth with sand paper and wiped clean.
If the old varnished surface is peeled or cracked then it will be necessary to remove the entire varnish as
described in para 13.41 and such removal shall be paid for separately outside the rate for varnishing. Further
the varnishing itself will have to be done like new work and will be paid for as such.
14.31.3.2 Application : The specification shall be same as described in 13.37.3.2 as far as applicable except
that the coats to be applied will be with the stipulated quality of varnish for finishing coat.

14.33 DOUBLE SCAFFOLDING

Specifications are same as described in sub head RCC work. (Figure 14.6)
14.34 FIXING OLD WIND TIES

14.34.1 Specified same as described in 14.5 above. Except for the old wind tie will be used for which
nothing extra will be paid. The old wind tie shall be properly cleaned off and anticorrosive bituminous
paint shall be applied before fixing the same at required location of the roof sheets with new J hook
and bolts and washers for resisting water from dripping through bolt of same size as existing in the
bolt tie to securing the same imposition.
14.34.2 Measurement
Work shall be measured in running meter
14.34.3 Rate
The rates are include the cost of labours and materials in all the operations described above.
14.35 BRICK WORK IN MUD MORTAR

14.35.1 Selection of clay for mud mortar
The clay or mixture of clays should preferably conform to the following mechanical composition.
Grain size analysis shall be done in accordance with the method given in IS 2720 (Part 4): 1986.
Clay 18-22 percent by weight
Silt 40-45 percent by weight
Sand 30-40 percent by weight
The total content of clay and silt be preferably not less than 60 percent by weight.
Note:- In case of soils which are more sandy or clayey than the limits specified above, the same
should be blended with more plastic clay or non-plastic materials as the case may be so as to bring
the mechanical composition within the above specified limits.
Since the mud mortar is susceptible to weathering mud mortar masonry may be used for temporary
structures and low rise structures having adequate lateral stability.
Thickness of mud mortar should not be more than 20mm in case of brick masonry works and
30mm in case of stone masonry works.
The masonry should preferably be plastered or pointed by cement or lime mortar externally to
avoid erosion of mortar from joints.
Concentrated load should be distributed by providing plain concrete or RCC bed blocks or by
using cement mortar masonry below the concentrated loads.
Note:- For mud mortar construction in seismic zones refer IS 4326 : 1976.
14.35.2 Preparation of Mortar

The soil for preparation of mud mortar should be processed so as to free from gravel coarse
sand (particle size greater than 2mm) lime and kankar particles vegetable matter, etc.
Coarse grit, kankar etc. if present should be removed by wet sieving.

The sieved clay should be allowed to dry and then blended with plastic clay or a non-plastic
locally available material (like rice husk, jute waste, wheat husk etc.) as the case may be so as to
bring the mechanical composition within the limits specified above.
Where wet sieving is not necessary, the soil shall be lightly broken up and wetted. The wet mass
shall be tempered over under the feet, repeatedly turned over big spades and then thoroughly
kneaded. The kneaded mass shall than be left for rempering for at least 24 hrs with the soil being
preferably covered with wet gunny bags.
Immediately before use in the masonry a small quantity of the prepared soil shall be mixed with a
further quantity of water to obtain the decide consistency and workability. The total moisture content
of the prepared mortar shall be in the range of 35 to 40 percent by weight of soil.
14.35.3 Field Test

For quick field observation and intermittent chicks, sample test as given in Annex-B may be
made.
If the ball prepared as given in Annex-B as deformed on drying and crumbles easily when pressed
lightly, it may be inferred that sand content excessive.
.If the ball is hard but shows cracks on the surface, then the sand content is insufficient.
If the soil is not found suitable, as inferred above the test should be repeated after modifying the
composition of the soil, such as by mixing different proportions of two soils or by addition of sand or
clay whichever is needed, for checking the stability.
ANNEX B
FIELD TEST FOR SOIL FOR MASONRY MUD MORTAR
B-1 The soil should be ground to a fine powder and mixed with sufficient water, added in small
quantities. The mix should than be kneaded into a plastic mass of the required consistency.
B-2. Take a handful of the soil prepared in B-1 and form into a ball of about 80mm diameter.
B-3. Keep the ball in the sun for drying. When dried, examine the ball for loss of shape and surface
cracks, if any.
Brick work shall be measured in cubic metres unless otherwise specified. Any extra work over the
specified dimensions shall be ignored. Dimensions shall be measured correct to the nearest 0.01 m
i.e. 1 cm. Areas shall be calculated to the nearest 0.01 sq mtrs and the cubic contents shall be
worked out to the nearest 0.01 cubic metres. All other specifications of brick work for such as bond,
laying, finishing of joints, scaffolding, measurements shall be followed same as a regular brick work.
The thickness of joints shall be kept 12mm uniformerly
14.35.5 Rate: The rate shall include the cost of all materials and labour involved in all the operations
described above.
14.36 BRASS CURTAIN RODS

14.36.1 Material
The brass curtain rods of required dia 20mm/25mm with wall thickness 1.25mm shall be provided
with 2 no. brass brackets fixed with brass screws to the wall by means of wooden plugs/PVC Rawl
Plugs. The size of brass screws shall not less than 60mm length.

Curtain road shall be measured in running meter two nos. brass brackets including necessary screw.
described above.
14.37. FIXING MS ROUND OR SQUARE BARS IN WOODEN FRAME OF WINDOW

The MS Square or Round Bars of 12mm shall be properly fixed on 50x6mm inner frame. The
outer frame shall be made with 50x6mm flat with clear distance of 50mm from the inner frame. Both
the frames should be fixed with a flat of 50x6mm with proper welding at a spacing of 30cm centre to
centre all around the frame. The 4 corners of the both frames shall be diagonally connected with
50x6mm flat with proper thorough welding and removal of sludge and proper grinding with machine
to have a smooth surface. The spacing of MS bars shall be kept 10cm centre to centre and the MS
flats shall be fixed to the wooden frame with the MS screws of 50mm size at a 30cm spacing along the
entire periphery of the outer frame. The frame should be properly cleaned with sand paper to receive
the coat of primer of ready mix zinc chromate yellow primer shall be applied on the entire surface
properly. The payment of the steel grill work shall be paid by weight.
Steel grid shall be measured in Kg.
14.37.2 Rate
It includes the cost of labour and material involved in all the operations described above including
fixing including coat of yellow zinc primer.
14.38 WOODEN KARRIES FOR ROOFING

The required size wooden karries of designated wood shall be procured. These should be properly
seasoned before using in the work and shall be hoisted with suitable hoisting by means of mechanical/
manual arrangements with suitable safety measures. A RCC band minimum 50mm thick shall be laid
on top of brick wall over which the wooden karries shall be placed at required spacing depending
upon the design/load of roof. The both end of the wooden karries having bearing on the wall to be
painted with bituminous paint.
The good quality wood preservative shall be applied all round the wooden karries.
Wooden karries shall be made in cubic meter and it includes every cost of material and labour/
T&P required for fixing the karries in position.
14.38.2 Rate
It includes the cost of labour and material involved in all the operations described above.
14.39. DOUBLE SCAFFOLDING SYSTEM UPTO SEVEN STOREY HEIGHT MADE WITH MS TUBE
The double scaffolding made with 40mm dia and 25mm dia pipe shall be erected along the wall
surface. The MS pipe of heavy duty with wall thickness 4mm shall be used for the scaffolding. The
scaffolding shall be erected in double row system and at every 9m height the extra 1 row of 40mm dia
pipe perpendicular to wall surface shall be provided to secure the both layer of vertical pipe in the
wall for better stability. It should be strong enough to with stand all coming load / wind pressure/tilt
etc. The double scaffolding consist of 2 rows of vertical with horizontal and diagonal bracing forming
essentially a structure independent of the building. The bottom of the scaffolding shall be fixed in
suitable MS chair on base plate of minimum 12mm thick and 25x25cm size. The plate should be
properly placed firm plate concrete floor. The frame work of scaffolding made with 40mm dia MS tube
1.5m centre to centre horizontal and vertical joint with cup and lock system and MS fixtures etc. MS

tube challies and MS tube staircase in scaffolding for working platform etc. shall also be provided.
The scaffolding system shall be stiffened with bracings, runners, connection with the building etc.
wherever required for inspection of work at required locations with essential safety features for the
workman etc. complete as per directions and approval of Engineer-in-charge.
Note:- 1. The condition of MS tube and required claddings should be in good condition and should
not have been used more than the specified time/nos. Scaffolding system shall remain the
property of the contractor after completion of work.
2. This item to be used for maintenance work judicially, necessary deduction for scaffolding in
the existing item to be done.
14.39.1 Measurement & Rate

The elevational area of the scaffolding shall be measured for payment in sqm. The payment will
be made once irrespective of duration of scaffolding.
14.40 REPAIR TO PLASTER IN PATCHES.

The repair to plaster of thickness 12mm to 20mm in patches of area upto 2.5 sqm shall be done
with white cement polymer modified self curing mortar. Before applying the mortar cutting the patch
in proper regular (square/ rectangle) shape, racking out joints and preparing the wall to receive the
plaster shall be done. The payment shall be made in area of patches measured in sqm.
Patch repair shall be measured in sqm.
described above.
14.41 – CLEANING
14.41.1 CLEANING OF WATER STORAGE TANKS
14.41.1.1 The Water Storage Tanks at terrace upto 2000 lt. capacity at all heights shall be cleaned
with pressure water jetting with chemical mixed water with suitable pump arrangement and followed
by coconut brushes, duster etc. including removal of silt, rubbish from the tank and cleaning the
tank with fresh water disinfecting with bleaching powder @0.5gm per litre capacity of tank including
marking the date of cleaning on the side of tank body with the help of stencil and paint and
disposing of malba all complete as per direction of Engineer-in-charge. (The old date already
written on tank should be removed with paint remover or black paint and if date is not written with
the stencil or old date is not removed deduction will be made Rs.0.10 per litre) (if during cleaning
any GI fittings or ball cock is damaged that is to be replaced by contractor at his own cost and
nothing extra will be paid on this account).
14.41.1.2 Measurement
Cleaning of water storage tank shall be measured in litre.
14.41.1.3 Rate: The rate shall include the cost of all materials and labour involved in all the operations
described above.
14.41.2 CLEANING AND DE-SILTING OF GULLY TRAP

14.41.2.1 The gully trap/chamber shall be cleaned and de-silted in following manner:
1. Removal of rubbish mixed with earth by deployment of sufficient manual labour.
2. Disposal of the accumulated malba, rubbish to the approved dumping ground with the help
of trolley/wheel barrows properly lined with PVC sheet to avoid splashes of the sewage/
rubbish on the ground.

All above mentioned 2 operations shall be done by making all adequate safety arrangement
to the labour including providing them medical aid, rubber gloves, helmets, masks, oxygen
cylinder etc. and make the site neat and clean after completion of work.
The payment to be making is inclusive of all operation like labour, material and T&P whichever
is required.
14.41.2.2 Measurement & Rate

Cleaning and de-silting of gully trap shall be measured and payment in numbers. The payment to
be making is inclusive of all operations like labours, materials and T&P whichever is required.
14.41.3 CLEANING OF CHOCKED SEWER LINE

14.41.3.1 The chocked / blocked sewer line shall be cleaned in following steps:
1. The manhole covers shall be kept open for same time before the cleaning of sewer line so
as to escape the foul gases.
2. Sucking the chocked malba material by diesel running, vehicle mounting hydraulic operated
suction/jetting cleaning machine with appropriate capacity as per requirement.
3. Disposal of the accumulated malba, rubbish to the approved dumping ground with the help
of trolley/wheel barrows properly lined with PVC sheet to avoid splashes of the sewage/
rubbish on the ground.
All above mentioned 2 operations shall be done in presence of supervisor and by making
all adequate safety arrangement to the labour including providing them medical aid, rubber
gloves, helmets, masks, oxygen cylinder etc.
14.41.3.2 Measurement & Rate

Cleaning and desilting of sewer line shall be measured and payment in numbers. The payment to
be making is inclusive of all operations like labours, materials and T&P whichever is required.
14.41.4 CLEANING OF UNDERGROUND SUMP, OVER HEAD R.C.C. TANK

The process of cleaning of underground sump, Over Head R.C.C. Tank (independent staging)
will be done in following operations:-
1. Tank shall be emptied of water by pumping & bottom shall be cleaned of silt and other
deposits.
2. Entire surface area of the sump shall be cleaned with pressure jetting of water mixed with
cleaning chemical atleast two times and thoroughly etc. and finally washing with simple
water jet to clean properly the wall surface.
3. Chlorination of RCC internal surface by liquid chlorine.
4. The treated surface shall be dried using air jetting and all loose particles shall be removal
from the surface.
5. Finally the surface shall be treated with ultraviolet radiation etc. as per direction of Engineer-
in-Charge.
All above mentioned four (4) operations shall be done by making all adequate safety
arrangement to the labour including providing them medical aid, rubber gloves, helmets,
masks etc.
Cleaning of internal surface area of underground sump, Over Head RCC tanks shall be measured
in sqm.
14.41. 4.2 Rate: The rate shall include the cost of all materials and labour and T&P involved in all the
operations described above.

14.42 DISCONNECTING DAMAGED OVERHEAD/TERRACE
The execution/operation of the item is as under:
1. Closing the water supply line tank by means gate valve /stop cock etc.
2. Emptying the water tank completely.
3. The Water tank supply connection will be disconnected and the delivery pipe line shall also
be disconnected by removing all the fitting and fixtures completely.
4. The delivery pipes from the bottom of the tank shall also be disconnected from the tank.
5. Removing the water storage tank from terrace and shifting it to the ground floor by mechanical
means or by manual with all safety reasons as directed by Engineer-in-charge.

The measurements of overhead/ terrace PVC water storage tanks of any size shall be measured
in numbers and payment shall be made on each basis.
14.43 REPLACEMENT OF OLD DAMAGED W.C. SEATS

The execution/operation of the item is as under:
1. Dismantling and taking out the old WC seat and “S” or “P” trap at site complete with all
operations including all necessary materials, labour and disposal of dismantled material i/c
malba, debris etc. including lead upto dumping ground.
2. Providing “S” or “P” trap and water closet squatting pan (Indian type) of approved brand of
good quality.
3. Fixing the W.C. with trap in position along with trap by making all arrangement of connecting
it to the flushing cistern. Thereafter the gap left in the filled up portion is to be leveled by
cement concrete 1:5:10 and floor tiles of same shade are also to be provided over it to match
the floor of the toilet.

The measurements and payment of replaced W.C Seats shall be made on each basis
14.44 CUTTING HOLES OF REQUIRED SIZE IN BRICK MASONRY WALL
Cutting holes of required size in brick masonry wall for fixing of exhaust fan including providing and
fixing 300mm dia PVC pipe conforming BIS-12818 and making good the same etc. complete. The
hole shall be cut with cutting tool by marking hole all round the circle with the help of power drill
machine so that the adjoining wall should not get damaged.

The measurements and payment of cutting holes and finishing etc. shall be made on each basis
14.45 DISMANTLING W.C. PAN OF ALL SIZES

Dismantling W.C. Pan of all sizes including disposal of dismantled materials i/c malba all complete
as per directions of Engineer-in-Charge. The W.C. seat is taken out along with trap and the area is
to be cleaned off all dust and rubbish etc. Thereafter the hole left in the flooring is to be leveled by
cement concrete 1:5:10 and floor tiles of same shade are also to be provided over it to match the
floor of the toilet room.

The measurements and payment of dismantling W.C. Pan of all sizes shall be made on each
basis.

14.46 HACKING OF CC FLOORING
Hacking the CC flooring including cleaning the surface etc. complete as per direction of the Engineer-in-
Charge. The hacking of CC flooring is done with chisel and hammer to make the top surface of flooring rough
before laying tile/ marble/granite flooring etc. The hacking should be at least 10 nos. in 30x30cm area of the floor.

The measurements and payment of hacking of CC flooring shall be made on sqm.
14.47 DISMANTLING 15 TO 40MM DIA G.I. PIPE

Dismantling 15 to 40mm dia G.I. pipe including stacking of dismantled pipes (within 50 metres lead) as
per direction of Engineer-in-Charge. The pipe dismantling is done from tap point to main line. The 15mm dia is
to be dismantled first and thereafter the dismantling/taking out the pipe shall proceed towards bigger dia pipe
at the last. The pipe is removed from its joints/sockets/T-section gently with pipe wrench/tool so that the old
pipe is not get damaged and the same can be reused where required. The old dismantle pipe will be stacked
dia wise and connected fittings are also to be stored properly for reuse.

The measurements and payment of Dismantling G.I. pipe shall be made on meter.
14.48 TAKING OUT EXISTING WOODEN DOOR SHUTTER AND RE-FIXING THE SAME AFTER REPAIRS
Taking out existing wooden door shutter, repair by de-screwing hinges etc. and re-fixing the repaired door
shutters to existing door frames, including replacement of hinges with screws etc. as required, all complete
as per the direction of the Engineer-in-charge. The old shutter is to be taken out by removing the screws from
the hinges by screw driver/screw fixing equipment (electric driven). Thereafter, the damaged part of the shutters
such as styles/ panels/veneering etc. is replaced with new one and the door shutter is prepared for re-fixing to
the door frame. During re-fixing the position of hinges if required may be shifted for proper anchorage with
50mm stainless steel screw with cross head. The re-fixing with butt hinges by means of screws is done with
the help of electric driven screw driving equipment. The whole door including chokhat is to be re-painted with
required colour to match the door and shutter with the same shade.

The measurements and payment shall be made on each basis.
14.49 WATER PROOFING TREATMENT WITH APP (ATACTIC POLYPROPYLENE POLYMERIC) MEMBRANE
Water proofing treatment of roofs with APP modified polymeric membrane shall be either five course, seven
course as specified in the item. In selecting the combinations of layers of APP membrane, consideration shall
be given to the type and construction of buildings, climate and atmospheric conditions and the degree of
permanence required. Five course treatment is a normal treatment suitable to moderate rainfall conditions (less
than 50 cm.) and seven course treatment is suitable for heavy rainfall (50 cm and above). Seven course treatment
with APP modified polymeric membrane 2.00 mm thick and weight 3.00 kg./sqm. to suitable for very heavy
conditions of rainfall (more than 150 cm.).
14.49.1 Materials
14.49.1.1 The bitumen primer shall conform to the requirements laid down in IS 3384.
14.49.1.2 APP Modified Membrane: It is a polymeric water proofing membrane manufactured to high
standards. It is five layered APP modified polymeric membrane with centre core as 20 micron HMHDPE/
100 micron HMHDPE High Molecular High Density Polythylene Film, is the heart of the membrane and
protects against water and moisture. The centre core is sandwiched on both sides by high quality polymeric
mix with properties of high softening point, high heat resistance and cold resistively to make it ideal for all
water proofing treatment. The polymeric mix is protected on both sides with 20 micron HMHDPE film. The
membrane is available in variable thickness and weights. Usual width is 1.0 m.
Important physical and chemical parameter of the membrane shall be as given in Table 14.5 for guidance.

TABLE 14.5
Centre Core Film Thickness Weight
20 micron HMHPDE 20 micron HMHPDE 1.5 mm 2.25 kg/ sqm.
100 micron HMHPDE 20 micron HMHPDE 2.00 mm 3.00 kg./ sqm.
Where proprietary brands Atactic Polyproplene modified polymeric membrane is proposed to be

used by the contractor, they shall conform in all respect to the specification in the preceding paras
and manufactured by a company of repute.
14.49.1.3 Bonding Material: This shall consist of blown type bitumen conforming to IS 702 or
residual bitumen 85/25 conforming to IS 73 heated to the correct working temperature of 180°C. The
penetration of the bitumen shall not be more than 40 when tested in accordance with IS 1203, unless
otherwise specified each coat of bonding material shall be of blown type bitumen of grade 85/25
heated to a working temperature of 180 degree C and applied @ 1.20 kg. per square metre of the
surface area.
14.49.1.4 Surface Finish: Surface finish shall be with brick tiles of class designation 100 grouted
with cement mortar 1:3 (1 cement : 3 fine sand ) with 2% integral water proofing compound by weight
of cement over a 12 mm thick layer of cement mortar 1:3 (1 cement: 3 fine sand) and finished neat,
as shown in Fig. 14.7. Surface finish shall be measured and paid for separately.
14.49.1.5 Preparation of Surface: The surface to be treated shall have a minimum slope of 1 to
120. This grading shall be carried out with cement concrete or cement plaster with coarse sand, as
desired, to the average thickness required and finished smooth. Such grading shall be paid for
separately.
Junctions between the roof and vertical faces of parapet walls, chimneys etc. shall be chased by
running triangular fillets 7.5 x 7.5 cm. size, cement concrete. At the drain mouths, the fillets shall be
suitably cut back and rounded off for easy application of water proofing treatment and easy flow of
water. Cement concrete where shall be 1:2:4 mix (1 Cement: 2 Coarse sand: 4 Graded stone aggregate
20 mm. Nominal size). The provision of fillets shall be deemed to be covered by the item of water
proofing and shall not be measured or paid for separately.
In existing roof where gola and drip course are provided at the junction of roof and vertical face
of parapet wall, chimney stacks, etc. These shall be dressed suitably and finished smooth so as to
ensure an easy and gradual turning of the flashing. Any dismantlement or forming and finishing
smooth the junction for forming the base of the flashing shall not be measured or paid for separately
and shall be deemed to form part of the preparation of the surface.
While the grading of roof surface is being done, it shall be ensured that the outlet drain pipe have
been fixed and mouth at the entrance have been eased and rounded off properly for easy flow of
water. When any pipe passes through the roof to be treated, angular fillet of shape shown in Fig.
22.11 shall be built around it for the water proofing treatment to be taken over it. These fillets shall
not be measured or paid for separately. For carrying over and tucking in the water proofing felts into
the parapet walls, chimneys stacks etc. a horizontal groove 6.5 cm. deep, 7.5 cm. wide section with
its lower edge at not less than 15 cm. above the graded roof surface shall be left on the inner face of
the same; during construction if possible. When such groove has not been left, the same shall be cut
out neatly and the base at rear of the groove shall be finished smooth with cement plaster 1:4 (1
cement: 4 coarse sand). Such cutting of the groove and its finishing smooth shall be part of the water
proofing or paid for separately. No deduction shall be made either for not making the groove or when
the latter has already been left in the masonry by the construction agency. Tucking in the water

proofing felt will be required where the parapet wall exceeds 45 cm. in the height from the graded
surface. Where the height is 45 cm. or less, no groove will be required as the water proofing treatment
will be carried over the top of the parapet wall to its full thickness. In the case of low dividing walls of
height 30 cm. or less, outlets therein shall be cut open for full height and the bottom and sides shall
be rendered smooth and corners rounded and such treatment shall not be measured and paid for
separately. Where expansion joints are left in the slab the provision of dwarf walls and/or RCC slabs
for covering them and finishing the surface smooth shall be the responsibility of the construction
agency, which had laid the roof slab and will not be included in the operation of water proofing. The
graded surface of the roof and concrete fillets and the faces of walls shall be thoroughly cleaned with
wire brushed and all loose scales etc. removed. The surface shall then be dusted off. Any crack in
the roof shall be cut to V section, cleaned and filled up flush with cement mortar slurry 1:4 (1 cement
: 4 coarse sand) or blown type petroleum bitumen of IS grade 85/25, or approved quality conforming
to IS 702. Such cleaning of the surface or treating the cracks shall not be paid for separately.
14.49.1.6 Treatment: The water treatment shall be of five or seven course as specified.
In seven course treatment, the first four courses shall be the same as for five course treatment.
The fifth course shall be a layer of APP modified polymeric membrane. The sixth course shall be a
coat of bonding material and the top most seventh course shall be of specified surface finish.
14.49.1.7 Laying
(a) First course shall be a coat of bitumen primer @ 0.40 kg per sqmt followed by subsequent
course as per treatment required.
(b) Drain outlets shall be given a four or six course treatment as specified for the roof in the
description of the item in the manner specified for the flat roof surface. Water proofing
treatment shall be carried into the drain pipe or outlets by at least 10 cm. The water proofing
treatment laid on the roof surface shall overlap the upper edge of the water proofing treatment
in the drain outlets by at least 10 cm.
(c) The APP modified polymeric membrane shall be cut to the required length, brushed clean
of dusting material and laid out flat on the roof to eliminate curls and subsequent stretching.
The membrane shall normally be laid in length in the direction of the slope and laying shall
be commenced at the lowest level and worked up to crest. The membrane shall not be laid
in single piece of very long lengths as they are likely to shrink; 6 to 8 m are suitable lengths.
The roof surface shall be cleaned and dry before starting the membrane treatment. Each
length of membrane shall be laid in position and rolled up for a distance of half its length.
The hot bonding material shall be poured on the roof across the full width of the rolled
membrane as the latter is steadily rolled out and pressed down. The pouring shall be so
regulated that the correct weight of bonding material per unit area is spread uniformly over
the surface. Excess bonding material that gets squeezed out at the ends shall be levelled
up as laying proceeds. When the first half of the strip of felt has been bonded to the roof,
the other half shall be rolled up and then unrolled on the hot bonding material in the same
way. Subsequent strips shall also be laid in the same manner.
Each strip shall overlap the preceding one by at least 7.5 cm. at the longitudinal edges and
10 cm. at the ends. All overlaps shall be firmly bonded with a blow lamp and levelling down
unevenness. The fourth layer of bonding material in the five course treatment shall be
carried out in a similar manner after the flashing has been completed.
(d) In a seven course treatment the fifth layers of membrane shall be laid in the manner already
described, taking care that laps in the membrane are staggered from those in the earlier
layer. The sixth layer of bonding material shall be carried out after the flashing is done.

(e) High Parapet Walls, Chimney Stacks etc.: Membrane shall be laid as flashing wherever
junctions of vertical and horizontal surfaces occur. Longitudinal laps shall be 10 cm. The
lower layer of flashing membrane in a six course treatment shall overlap the roof water
proofing by not less than 20 cm. while the upper layer shall overlap the roofing felt by 10
cm. The minimum overlap of the flashing membrane in five course treatment over the roofing
membrane shall be 10 cm.
The flashing shall consist of the same five or seven course treatment as for the roof except
that the final course shall be replaced by an application of 12 mm thick cement plaster 1:3
on the vertical and sloping faces only, of the flashing as shown in Fig 14.8. The overlap
along the length of flashing shall stagger with those in the second layer of flashing membrane
(in a seven course treatment and with the joints in the roof membrane).
The upper edge of the finishing membrane shall be well tucked into the flashing grooves in
the parapet, chimney stacks etc. to a depth of not less than 6.5 cm. Corresponding
applications of bonding material shall also be made. The flashing treatment shall be firmly
held in place in the grooves with wood edges at intervals and the grooves shall be filled up
with cement mortar 1:4 (1 cement: 4 coarse sand) or cement concrete 1:2:4 (1 cement: 2
coarse sand : 4 graded stone aggregate 6 mm nominal size) and surface finished smooth
with the rest of the wall. The cement work shall be cured for 7 days. When dry, the exposed
plaster joints of grooves shall be painted with bitumen and two coats of bituminous solution
shall be applied on the vertical and sloping surface of flashing (see Fig. 14.7).
After the top flashing membrane layer has been fixed, the penultimate layer of bonding
material shall be applied over the roofing membrane and the horizontal overlaps and vertical
and sloping surfaces of the flashing at the specified rate.
(f) Low Parapet Walls: Where parapet walls are of height 45 cm. or less, membrane flashings
shall be provided in the same manner as for flashings in the case of high parapet walls
except that the upper edge shall be carried upto the full height of the wall and taken right
across the top of the parapet and down on the external vertical faces to a minimum distance
of 5 cm. (see Fig 14.8).
(g) Low Dividing Walls: Where low dividing walls or inverted beams are met with, the same shall
be covered with a four or six layer treatment as for the main roof, the latter bearing carried
down both sides of the wall and overlapping the roofing treatment as in the case of flashing
of high parapet walls (see Fig. 14.10).
Drain outlets where formed in the low dividing walls, shall be given water proofing treatment
of the same number of courses as specified for the flat roof surface. The bottom and sides
shall be so treated that all overlaps are in the direction of flow of drainage.
(h) Expansion Joints: Where the expansion joints are provided in the slabs, the joints and their
cover slabs shall be suitably treated with water proofing. A typical sketch of an expansion
joint with the RCC slabs on either side of the joint turned vertically up and dwarf walls by not
less than 7.5 cm. and are provided with throatings on their underside along their length.
The water proofing treatment shall be taken up the sloping junction fillets and the vertical
faces of the walls to the underside of the cover slabs. The cover slabs are given the water
proofing treatment like the roofs slabs, after the cross joints between adjacent cover slabs
are first sealed with 15 cm width of roofing felt struck to them with bitumen. The water
proofing treatment shall be carried down the sides of the cover slabs to their full thickness.
Care shall be taken to see that overlaps if any in the roofing over the cover slabs stagger
with the joints between cover slabs.

The formation of the expansion joints and provision of the cover slabs shall be the responsibility of
the construction agency. The formation of the junction fillets and the water proofing treatment of the
joint and cover slabs shall be carried out by the water proofing agency. Nothing agency extra shall
be paid for the sealing of the cross joints in the cover slab with 15 cm. width of bitumen strips.
(i) Pipes: Where vertical pipe outlets are met with, 7.5 x 7.5 cm fillets of lime or cement concrete of the
type and section shown in Fig. 14.10 shall be provided and flashing of four or six course treatment,
same as for the roofing treatment shall be laid.
The upper edge of the flashing shall be laid sloping down forward and butted against the pipe and annular
depression so formed shall be filled with hot bitumen. A circular metal collar in the shape of an inverted
truncated cone shall be fixed on the pipe to throw off the rain water clear of the flashing and this shall be paid
for separately.
14.49.1.8 Measurement: Length and breadth shall be measured correct to a cm. The area shall be calculated in
square metres correct to two places of decimal. Measurements shall be taken over the entire exposed area of
roofing and flashing treatment including flashing over low parapet walls, low dividing walls and expansion joints and
at pipe projections etc. Overlaps and tucking into flashing grooves shall not be measured. Vertical and sloping
surfaces of water proofing treatment shall also be measured under the five or seven course treatment as the case
may be, irrespective of the fact that the final course is replaced by bitumen primer. No deduction in measurements
shall be made for either openings or recesses for chimney stacks, roof lights and the like, for areas upto 0.4 sqm
nor anything shall be paid for forming such openings. For areas exceeding 0.40 sqm deduction will be made in
measurements for full opening and nothing extra shall be paid for forming such openings.
14.49.1.9 Rate: The rate shall include the cost of all labour and materials involved in all the operations
described above. The top most layer shall be paid for separately.
Clause 14.49 brought from Sub Head 22 (Water Proofing) clause no 22.11
14.50 FIVE LAYERED WATER PROOFING TREATMENT WITH ATACTIC POLYPROPYLENE POLYMER
MODIFIED PREFABRICATED MEMBRANE
14.50.1 Atactic Polypropylene Polymer modified prefabricated five layer water proofing membrane shall be of
thickness as specified. In selecting thickness of membrane due consideration shall be given to the type and
construction of building, climate and atmospheric condition and permanence required. Five layered treatment
2.00 mm thick with glass fibre is with a normal duly treatment suitable for pitched roofs. Five layered 3.00 mm
thick with glass fibre matt treatment is suitable for moderate condition of rainfall (50 to 150 mm) and fine
layered 3.00 mm thick with non-woven polyester matt treatment is suitable for heavy condition of rainfall.
14.50.1.1 Materials
Bitumen primer for bitumen membrane shall have density at 25°C in the range of 0.87 - 0.89 kg./litre and
viscosity of 70-160 CPS primer shall be applied @ of 0.40 litre/sqm.
14.50.1.2 Atactic Polypropylene Polymer Modified Prefabricated Membrane: It is a polymeric water proofing
membrane. This shall be one of the following types:
(i) 2 mm thick with glass fibre matt.
(ii) 3 mm thick glass fibre matt.
(iii) 3 mm thick with non-woven polyester matt.
It is prefabricated five layered black finish water proofing membrane comprising of centre core of 50 gsm.
Glass fibre matt/170 gsm nonwoven polyester matt sandwiched on both sides by APP polymer modified
bitumen which is protected on both sides by 20 micron thermofusible polyethylene sheet. Composite thickness
of the membrane including all five layers shall be 2/3 mm with glass fibre matt and 3 mm with non woven
polyester matt. It is available in 1 m width and variable lengths.

Physical and chemical parameters of the membrane shall be as given in Table 14.6
TABLE 14.6
SI. No. of Layers Thickness Elongation at Joint Tear strength Softening Cold
No. 23° C in strength in in longitudinal Point flexibility
longitudinal longitudinal Transverse
transverse and direction
direction Transverse
direction
1 2 3 4 5 6 7 8
1 Five Layered 2 mm 3 N/5 cm. 350/300 60/80 N 150° -2°C
reinforced with N/5 cm.
fibre glass
2 Five layered 3 mm 3.3 N/5 cm. 350/3000 60/80 N 150° -3°C
reinforced with N/5 cm.
fibre glass
3 Five layered 3 mm 40/50 N/5 650 N/450 300/250 N 150° -2°C
reinforced with cm. N/5 cm.
non-woven
polyester matt.
When tested Atactic polypropylene modified black finished is proposed to be used shall conform in all
respects to the specification in the preceding paras. The work should be got done through authorized applicator/
specification agency.
14.50.1.3 Preparation of Surface: The surface to be treated shall have a minimum slope of 1 in 120 or as
specified, provision specified in clause 14.49.1.5 shall apply for preparation of surface except for pitched roof
where surface shall be cleaned off any loose material dust etc.
To ensure good adhesion between the surface and water proofing treatment suitable method to dry the
surface shall be adopted. All hair line cracks in the surface should be filled with approved sealant.
14.50.1.4 Treatment: The water proofing shall consist of prefabricated five layered 2 mm / 3 mm membrane
as shown in Fig. 14.11. The choice of 2 mm or 3 mm membrane will depend on the type of roof i.e. pitched or
flat and importance of building, durability, cost and rainfall etc.
14.50.1.5 Laying: Bitumen primer @ 0.40 lts/sqm shall be applied to the prepared roof, drain and all other
surfaces where polymer modified membrane is to be laid. The five layered water proofing membrane shall be
laid using Butane torch and sealing all joints and preparing the surface complete. Drain outlets shall be given
same treatment as specified for the roof in the description of the item in the manner specified for the flat roof
surface. Water proofing treatment shall be carried into the drain pipe or outlets by at least 10 cm. The water
proofing treatment laid on the roof surface shall overlap the upper edge of the water proofing treatment in the
drain outsets by at least 10 cm.
The APP polymer modified prefabricated water proofing membrane shall be cut to the required length.
Water proofing membrane shall normally be laid in length in the direction of the slope and laying shall be
commenced at the lowest level and worked upto crest. APP water proofing membrane shall be laid in 6 to 8 m
lengths. The roof surface shall be cleaned and bitumen primer shall be applied in the correct quantity, over this
specified water proofing membrane shall be laid with butane torch after allowing 24 hours for primer to dry.
Each strip shall overlap the preceding one by at least 10 cm. at the longitudinal edges and 15 cm. at the ends.
All overlaps shall be firmly bonded with bitumen primer and levelled by heating the overlap with butane torch.

If the roof is accessible the treatment is protected by brick tiles laid over 12 mm thick cement mortar of
specified grade bedding and joints sealed with cement mortar of which shall be measured and paid for separately.
APP water proofing membrane shall be laid as flashing wherever junction of vertical and horizontal surfaces
occur. Longitudinal laps shall be 10 cm. The upper edge of flashing membrane shall be well tucked into the
flashing grooves in the parapets, chimney stack etc. to a depth of not less than 6.5 cm; corresponding
applications of primer coat shall also be made. The flashing treatment shall be firmly held in the grooves and
it shall be sealed with the approved sealant after terminating the membrane.
Where parapet walls are of height 45 cm or less AP water proofing membrane flashing shall be provided in
the same manner as for splashing in the core of high parapet walls except that upper edge shall be carried out
the full height of the wall and taken right across the top of the parapet and down on the external vertical faces
to a minimum distance of 5 cm.
Where low dividing walls or inverted beams are met with, the same treatment shall be provided as for the
main roof, the lateral bearing carried down both sides of the wall and overlapping the roof treatment.
Drain outlets where formed in the low dividing walls, shall be given water proofing treatment same as for
the main roof.
Where the expansion joints are provided in the slabs, the joints and their cover slabs shall be suitably
treated with water proofing treatment. A typical sketch of an expansion joint with the RCC slabs on either side
of the joint turned vertically up and covered with precise RCC cover slabs as given in Fig. 14.10. The cover
slabs shall cover the vertical turned up dwarf walls by not less than 7.5 cm and are provided with throatings on
their underside along their length. The water proofing treatment shall be taken up the slopping junction fillets
and the vertical faces of the walls to the underside of the cover slabs are given the water proofing treatment like
the roof slabs, after the cross joints between adjacent cover slabs are first sealed with 15 cm. width of roofing
felt struck to them with bitumen. The water proofing treatment shall be carried down the sides of the cover
slabs to their full thickness. Care shall be taken to see that overlaps if any in the roofing over the cover slabs
stagger with the joints between cover slabs.
The formation of the expansion joints and provision of cover slabs shall be the responsibility of construction
agency. The formation of the junctions fillets and the water proofing treatment of the joint and cover slabs shall
be carried out by the water proofing agency. No extra shall be paid for the junction fillets or for the sealing of
the cross joints in the cover slab with 15 cm. width of bitumen strips.
14.50.1.6 Measurements: Length and breadth shall be measured correct to a cm. The area shall be calculated
in square metres correct to two places of decimal.
Measurement shall be taken over the entire exposed area of roofing and flashing treatment including
flashing over low parapet walls, low dividing walls and expansion joints at pipe projections etc. overlaps and
tucking into flashing grooves shall not be measured.
No deduction in measurements shall be made for either openings or recesses for chimney stacks, roof
lights and the like, for areas upto 40 square decimeter (0.4. sqm.) nor any thing shall be paid for forming such
openings. For areas exceeding 0.40 sqm. deductions will be made in measurements for full opening and
nothing extra shall be paid for forming such openings.
14.50.1.7 Rate: The rates shall include the cost of all labour and materials involved in all the operations
described above.

14.51 EXTRA FOR COVERING OF APP MODIFIED PREFABRICATED MEMBRANE WITH GEOTEXTILE
14.51.1 If the water proofing treatment of flat roof has been done with APP modified five layered membrane and
the roof is accessible, a separation layer on top of membrane should be laid before any protected treatment
is done. Brick tiles in cement mortar or 25 mm thick cement concrete 1:2:4 shall be laid as final layer as
shown in Fig. 14.11.
Geotextile 120 gm. Non woven 100% polyester of thickness 1.0 to 1.25 mm manufactured by a company
of repute shall be used.
Geotextile of the specified thickness is bonded to the water proofing membrane with intermittent touch by
heating the membrane by Butane torch as per manufacturing recommendations.
14.51.2 Measurements: Length and breadth shall be measured correct to two places of decimal, measurement
shall be taken over the entire exposed area of roofing.
14.51.3 Rate: The rate shall include the cost of all labour and material involved in all the operation described
above. Final layer of brick tiles or 25 mm thick cement concrete shall be measured and paid for separately.
14.52 PROVIDING ROUND THE CLOCK SECURITY GUARD WITHOUT GUN

Providing round the clock healthy security guard without gun for watch & ward of Government premises
and its all belongings by deploying neatly dressed security guards in 8 hour’s shift including necessary
T&P like torch, lathi and uniform etc. complete, as per the direction of Engineer-in-charge.(One job means
8 hour’s duty). Minimum qualification of security guard should be 10th class passed.
14.53 PROVIDING ROUND THE CLOCK SECURITY GUARD WITH GUN

Providing round the clock healthy security guard with gun for watch & ward of Government premises and
its all belongings by deploying neatly dressed security guards in 8 hour’s shift including necessary T&P like
torch, lathi and uniform etc. complete, as per the direction of Engineer-in-charge.(One job means 8 hour’s
duty). Minimum qualification of security guard should be 10th class passed.
The suggestive condition for item no. 14.52 & 14.53 are as under:-
1. The agency should have been registered with M/o Defence or Registrar Office for purpose of watch &
ward.
2. The Manpower deployed for the watch & ward will be in proper uniform.
3. The agency should get the employees under valid insurance till whole period of agreement.
4. During period of watch & ward any kind of loss / theft / damage to the govt. property / premises will
be compensated by the agency.
5. In case of any loss of material/damage of the property during the watch & ward period the FIR to the
police will be lodged immediately.
6. The Manpower deployed for the work shall be well equipped with torch, lathi, whistle, gun of valid
license from appropriate authority whatsoever as per requirement of the work.
14.53.1 Measurements:
The mode of measurements of security guard shall be measured on job/shift basis around the clock
(8hrs x 3 shifts for 24 hours) and complete month.
14.53.2 Rate: The rate of security guards on job basis and i/c the cost of all labour and T&P involved in all the
operation described above.

FIXING OF FAN CLAMPS IN EXISTING R.C.C. SLABS
Sub Head : Repairs to Buildings

Clause : 14.12
Drawing Not to Scale

All dimensions are in mm
Fig. 14.1 : Fixing of Fan Clamps in Existing R.C.C. Slabs

TERMINOLOGY TIMBER DOOR, WINDOW & VENTILATOR COMPONENTS

Clause : 14.16
WINDOWS AND VENTILATORS

Fig. 14.2 : Terminology Timber Door, Window & Ventilator Components

FLUSH BOLTS

Clause : 14.18.3

Fig. 14.3 : Flush Bolts

FLOOR DOOR STOPPER

Clause : 14.18.4
Floor Door Stopper - Cast Type
Dimensions
Thickness of A B C Casting Screw Designation No. of Holes
Door Shutter T1 No. For T1
30 35.0 ± 0.5 140.0 ± 0.5 13 4.5 ± 0.3 9 4
–0
35 40.0 ± 0.5 140.0 ± 0.5 8 4.5 ± 0.3 9 4

–0
40 45 ± 0.5 150.0 ± 0.5 13 4.5 ± 0.3 9 4

–0
45 50.0 ± 0.5 150.0 ± 0.5 8 4.5 ± 0.3 9 4
–0

Fig. 14.4 : Flush Door Stopper

WINDOW STAY

Clause : 14.18.6

Fig. 14.5 : Window Stay

TYPICAL DETAILS OF MULTI-STAGE SHUTTERING

Clause : 14.33
SUSPENDED FLOOR-MULTI STAGE SHUTTERING

(VERTICAL SECTION)
All Members are of Steel
Fig. 14.6 : Typical Details of Multi-Stage Shuttering

Clause : 14.49
Fig. 14.7 : Five Course Water Proofing Treatment with APP Modified Polymeric Membrane

Clause : 14.49.1.7
Fig. 14.8 : Grading Chajja with Cement Mortar 1:3/1:4

Clause : 14.49.1.7
Fig. 14.9 : Grading Roof Slab with Cement Concrete

Clause : 14.49.1.7
Diagrams Not to Scale

Fig. 14.10 : Water Proofing

Clause : 14.51
Fig. 14.11 : Five Layers Water-Proofing Treatment with APP Modified Prefabricated Membrane

SUB HEAD : 15.0
DISMANTLING AND DEMOLISHING
731
CONTENTS
15.0 Terminology 736
15.1 General 736
15.2 Recommendations for Demolition of Certain Special 737

Types and Elements of Structures
15.3 Measurements 739
15.4 Rates 741
Fig. 15.1 Demolition of Jack Arches 742
Fig. 15.2 Demolition of Masonry and Brickwork Arches 743
Fig. 15.3 Hand Demolition of In-Situ Concrete Structure 744
733 SUB HEAD 15.0 : DISMANTLING AND DEMOLISHING


1. IS 1200 (Pt - XVIII) Method of Measurements of Building and Civil Engineering Works
(Part -XVIII) Demolition and Dismantling
2. IS 4130 Demolition of Buildings-

15.0 DISMANTLING AND DEMOLISHING
15.0 TERMINOLOGY
(i) Deconstruction – Means a selective demolition in which salvage, reuse and recycling of
demolished structure is maximized. The term ‘Dismantling’ implies carefully separating the
parts without damage and removing. This may consist of dismantling one or more parts of the
building as specified or shown on the drawings.
(ii) Demolition: The term ‘Demolition’ implies breaking up. This shall consist of demolishing whole
or part of work either manually or using mechanical force (various equipment) or by implosion
using explosion, including all relevant items as specified or shown on the drawings.
15.1 GENERAL
This chapter relates to buildings only.
15.1.1 Precautions
15.1.1.1 All materials obtained from dismantling or demolition shall be the property of the Government
unless otherwise specified and shall be kept in safe custody until they are handed over to the Engineer-in-
Charge/ authorized representative.
15.1.1.2 The demolition shall always be well planned before hand and shall generally be done in reverse
order of the one in which the structure was constructed. The operations shall be got approved from the
Engineer-in-Charge before starting the work.
Due care shall be taken to maintain the safety measures prescribed in IS 4130 and construction and demolition
waste management rules 2016 shall be followed.
15.1.1.3 Necessary propping, shoring and or under pinning shall be provided to ensure the safety of the
adjoining work or property before dismantling and demolishing is taken up and the work shall be carried out in
such a way that no damage is caused to the adjoining work or property. Wherever specified, temporary
enclosures or partitions and necessary scaffolding with suitable double scaffolding and proper cloth covering
shall also be provided, as directed by the Engineer-in-Charge. It shall be ensured that no dust is generated
while demolishing. Demolition Rules – 2016 shall be followed.
15.1.1.4 Necessary steps shall be taken to keep noise and dust nuisance to the minimum. All work needs
to be done under the direction of Engineer-in-Charge. Helmets, goggle, safety belts etc., should be used
whenever required and as directed by the Engineer-in-Charge. The demolition work shall be proceeded with in
such a way that it causes the least damage and nuisance to the adjoining building and the public. Barricading
shall be provided as per NGT guidelines.
15.1.1.5 Dismantling shall be done in a systematic manner. All materials which are likely to be damaged by
dropping from a height or by demolishing roofs, masonry etc. shall be carefully removed first. Chisels and
cutters may be used carefully as directed. The dismantled articles shall be removed manually or otherwise,
lowered to the ground (and not thrown) and then properly stacked as directed by the Engineer-in-Charge.
15.1.1.6 Where existing fixing is done by nails, screws, bolts, rivets, etc., dismantling shall be done by
taking out the fixing with proper tools and not by tearing or ripping off.
15.1.1.7 Any serviceable material, obtained during dismantling or demolition, shall be separated out
and stacked properly as directed by the Engineer-in-Charge within a lead of 50 meters. All unserviceable
materials, rubbish etc. shall be disposed offat authorized locations by urban local bodies as directed by
the Engineer-in-Charge.
15.1.1.8 The contractor shall maintain/disconnect existing services, whether temporary or permanent, wherever
required by the Engineer-in-Charge.

15.1.1.9 No demolition work should be carried out at night especially when the building or structure
to be demolished is in an inhabited area.
15.1.1.10 Appropriate screens shall be placed where necessary to prevent injuries due to falling
pieces.
15.1.1.11 Water spray shall be used to reduce dust while tearing down plaster from brick work.
15.1.1.12 Safety belts shall be used by labourers while working at higher level to prevent falling
from the structure. Wherever, possible mechanized working platform shall be used.
15.1.1.13 First-aid equipment shall be made available at all demolition works of any magnitude.
15.2 RECOMMENDATIONS FOR DEMOLITION OF CERTAIN SPECIAL TYPES AND ELEMENTS

OF STRUCTURES
15.2.1 Roof Trusses If a building has a pitched roof, the roof structure should be removed to wall
plate level by hand method. Sufficient purlins and bracing should be retained to ensure stability of
the remaining roof trusses while each individual truss is removed progressively.
15.2.1.1 Temporary bracing should be added, where necessary, to maintain stability. The end frame
opposite to the end where dismantling is commenced, or a convenient intermediate frame should be
independently and securely guyed in both directions before work starts.
15.2.1.2 On no account should the bottom tie of roof trusses be cut until the principal rafters are
prevented from making outward movement.
15.2.3 Heavy Floor Beams Heavy bulks of timber and steel beams should be supported before
cutting at the extremities and should then be lowered to a safe working place.
15.2.4 Jack Arches Where tie rods are present between main supporting beams, these should not
be cut until after the arch or series of arches in the floor have been removed. Particular care should
be exercised and full examination of this type of structure undertaken before demolition is commenced
(see Fig. 15.1). The floor should be demolished in strips parallel to the span of the arch. rings (at
right angles to the main floor beams).
15.2.5 Brick Arches

15.2.5.1 Expert advice should be obtained and at all stages of the demolition, the closest supervision
should be given by persons fully experienced and conversant in the type of work to ensure that the
structure is stable at all times.
15.2.5.2 As much dead load as possible may be removed provided it does not interfere with the
stability of the main arch rings but it should be noted that the load-carrying capacity of many old
arches relies on the filling between the spandrels. On no account should the restraining influence of
the abutments be removed before the dead load of the sprandrel fill and the arch rings are removed.
15.2.5.3 The normal sequence of demolition is as shown in Fig. 15.2-A, namely:

(a) Remove spandrel in filling down to the springing line,
(b) Remove the arch. rings and
(c) Remove the abutment.
15.2.5.4 Special temporary support shall be provided in the case of skew bridges.

15.2.5.5 A single span arch. can be demolished by hand by cutting narrow segments progressively
from each springing parallel to the span of the arch until the width of the arch has been reduced to
a minimum which can then be collapsed (see Fig. 15.2B).
15.2.5.6 Where it is impossible to allow debris to fall to the ground below, centering designed to
carry the load should be erected and the arch demolished progressively. The design of the centering
should make appropriate allowance for impact.
15.2.5.7 Where deliberate collapse is feasible the crown may be broken by the demolition ball method
working progressively from edges to the centre (see Fig. 15.2C).
15.2.5.8 Collapse of the structure can be effected in one action by the use of explosives. Charges
should be inserted into boreholes drilled in both arch and abutments. This method is the most effective
for demolition of tall viaducts.
15.2.5.9 In multi-span arches before individual spans are removed, lateral restraint should be provided
at the springing level. Demolition may then proceed as for a single span, care being taken to demolish
the spandrels down to the springing line as the work proceeds (see Fig. 15.2D). Where explosives
are used it is preferable to ensure the collapse of the whole structure in one operation to obviate the
chance of leaving unstable portions standing.
15.2.6 Cantilevers (Not part of a Framed Structure)

A cantilever type of construction depends for its stability on the super imposed structure. Canopies,
cornices, staircases and balconies should be demolished or supported before the tailing down load
is removed.
15.2.7 In-situ Reinforced Concrete

15.2.7.1 Before commencing demolition, the nature and condition of the concrete, the condition and
position of reinforcement, and the possibility of lack of continuity of reinforcement should be
ascertained.
15.2.7.2 Attention should be paid to the principles of the structural design to determine which parts
of the structure depend on each other to maintain overall stability.
15.2.7.3 Demolition should be commenced by removing partitions and external non-load bearing
cladding. It should be noted that in some buildings the frame may rely on the panel walls for stability.
15.2.7.4 Where hard demolition methods are to be used, the following procedures should be used.
(a) Reinforced Concrete Beams
For beams,a supporting rope should be attached of preferably at two or three locations
to the beam. Then the concrete should be removed from both ends by pneumatic drill
and the reinforcement exposed. The reinforcement should then be cut in such a way
as to allow the beam to be lowered under control to the floor (see Fig. 15.3A).
(b) Reinforced Concrete Columns
For columns, the reinforcement should be exposed at the base after restraining wire
guy ropes have been placed round the member at the top. The reinforcement should
then be cut in such a way as to allow the column to be pulled down to the floor under
control. (see Fig. 15.3B for sequence of operations).
(c) Reinforced Concrete Walls Reinforced concrete walls should be cut into strips and
demolished as for columns (Fig. 15.3C).

15.3 MEASUREMENTS
15.3.1 All work shall be measured net in the decimal system, as fixed in its place, subject to the
following limits, unless otherwise stated hereinafter.
(a) Dimensions shall be measured correct to a cm.
(b) Areas shall be worked out in sqm correct to two places of decimal.
(c) Cubical contents shall be worked out to the nearest 0.01 cum.
15.3.2 Parts of work required to be dismantled and those required to be demolished shall be
15.3.3 Measurements of all work except hidden work shall be taken before demolition or dismantling
and no allowance for increase in bulk shall be allowed.
15.3.4 Specifications for deduction for voids, openings etc. shall be on the same basis as that
adopted for new construction of the work.
15.3.5 Work executed in the following conditions shall be measured separately.

(a) Work in or under water and/or liquid mud
(b) Work in or under foul position.
15.3.6 Roofs
(i) Roof coverings generally including battens boarding, mats, bamboo jaffari or other subsidiary
supports shall be measured in square metres except lead sheet roof covering which shall
be measured in quintals (15.2.3) and stone slab roof covering which shall be measured in
cubic metres.
(ii) Ridges, hips and valleys shall be girthed and included with the roof area. Corrugated or
semi corrugated surfaces shall be measured flat and not girthed.
(iii) Mud phuska on roofs shall be measured in cubic metres.
(iv) Lead sheets in roofs shall be measured in quintals and hips, valleys, flashings, lining to
gutter etc. shall be included in this weight.
(v) R.B. or R.C.C. roofs shall be measured as specified in 15.3.11.
(vi) Supporting members, such as rafters, purlins, beams joists, trusses etc. of wood shall be
measured in cubic metres and steel or iron sections, in quintals.
15.3.7 Ceiling
(i) The stripping of ceilings shall be measured in square metres.
(ii) Dismantling of supporting joists, beams, etc. shall be measured in cubic metres or in quintals
as specified in 15.3.6(vi).
(iii) Height above floor level, if it exceeds 3.5 m shall be paid for separately.
15.3.8 Flooring and Pavings

Dismantling of floors (except concrete and brick floors) shall be measured in square metres. Supports
such as joints, beams etc. if any shall be measured as per 15.3.6(vi). Concrete and bricks paving
shall be measured as per 15.3.9.
15.3.9 Concrete and Brick Roofs and Suspended Floors

Demolition of floors and roofs of concrete or brick shall be measured in cubic metres. Beams
cantilevers or other subsidiary supports of similar materials, shall be included in the item. In measuring
thickness of roofs provided with water proofing treatments with bitumen felts, the thickness of water
proofing treatment shall be ignored.

15.3.10 Walls and Piers
(i) Taking down walls and independent piers or columns of brick, stone or concrete shall be
measured, in cubic metres. All copings, corbels, cornices and other projections shall be
included with the wall measurements.
(ii) In measuring thickness of plastered walls, the thickness of plaster shall be ignored.
(iii) Ashlar face stones, dressed stone work, pre-cast concrete articles, etc. if required to be
taken down intact shall be so stated and measured separately in cubic metres.
(iv) Cleaning bricks stacking for measurements including all extra handling and removal and
disposing off the rubbish as stated shall be enumerated in thousand of cleaned bricks.
(v) Cleaning stone obtained from demolished/dismantling stone masonry of any description
including ashlar facing dressed stone work, stone slabs or flagging and pre-cast concrete
blocks including all extra handling and disposing off the rubbish as stated shall be measured
in cubic meters of cleaned stone.
(vi) Honey comb works or cavity walls of bricks stone or concrete shall be measured as solid.
15.3.11 Reinforced Concrete and Brick Work

Reinforced concrete structures and reinforced brick roofs and walls shall be measured in cubic
meters and if reinforcement is required to be salvaged, it shall be so stated.
Where reinforcement is required to be separated, scraped and cleaned, the work shall be measured
separately in quintal of salvaged steel.
15.3.12 Partitions, Trellis Work etc.

Partitions or light walls, of lath and plaster, trellis work, expanded metal, thin concrete or terracotta
slabs and other similar materials including frame work if any shall be measured in square meters
stating the over all thickness.
15.3.13 Wood Work

All wood work including karries average 40 sq cm or over in section, shall be measured in cubic
meters, while that under 40 sq cm in section, in running meters. Ballies shall be measured in running
meters.
Boarding including wooden chajjas and sun shades along with supports shall be measured in
square meters in its plane.
15.3.14 Steel and Iron Work

(i) All steel and iron work shall be measured in quintals. The weight shall be computed from
standard tables unless the actual weight can readily be determined.
(ii) Riveted work, where rivets are required to be cut, shall be measured separately.
(iii) Marking of structural steel required to be re-erected shall be measured separately.
(iv) In framed steel items, the weight or any covering material or filling such as iron sheets and
expanded metal shall be included in the weight of the main article unless such covering is
not ordered to be taken out separately.
15.3.15 Doors and Windows

Dismantling of doors, windows, clerestory windows, ventilators etc. (wood or metal) whether done
separately or along with removal of wall by making recess in the wall shall be enumerated. Those
exceeding 3 sqm each in area shall be measured separately. The item shall include removal of
chowkhats architraves, holdfasts and other attachments.
If only shutters are to be taken out it shall be measured separately.

15.3.16 Pipes and Sewer Lines
(i) Water pipe lines including rain water pipes with clamps and specials, sewer lines (salt
glazed ware or concrete) etc. shall be described by their diameter and length measured in
running metres inclusive of joints.
(ii) If the joints, special and fittings etc. are required to be separated, it shall be so stated and
enumerated.
(iii) Pucca drains shall be measured under relevant items.
(iv) Valve cistern, public fountain platform, fire hydrants, etc. shall be enumerated.
(v) Manholes and inspection chambers shall be enumerated stating the size and depth of
manhole/inspection chamber. They shall be classified into different groups depending upon
the depth, in unit of half and one metre depth. The depth of the manhole shall be the
distance between the top of manhole cover and invert level of the drain.
(vi) Ventilating shafts, gully traps, flushing cisterns and other appurtenant items of work shall
be enumerated.
15.3.17 Posts or Struts

Posts or struts (wood, steel or RCC) section including taking out embedded portion shall be
measured in running meters.
15.3.18 Fencing Wire Mesh

Wire mesh fencing of any type with frame shall be measured in square metres.
15.3.19 Glazing
Taking out any portion of serviceable glass except polished plate, from old sashes, skylights, etc.
(any thickness, weight or size) raking out old putty, etc. shall be measured in square meters.
Irregular circular panes shall be measured as rectangle or square enveloping the same. The width
and height being measured correct to the nearest 0.5 cm.
15.3.20 Road Work

(i) Different types of road surfaces shall be measured separately.
(ii) Road surfaces metalling or soling (base) shall be measured in square meters.
(iii) Concrete paving shall be measured as in 15.3.8 or 15.3.9 as the case may be.
15.4 Rates
The rate shall include the cost of all labour involved and tools used in demolishing and dismantling
including scaffolding. The rate shall also include the charges for separating out and stacking the
serviceable material properly and disposing off unserviceable material within a distance of 50 meters.
The rate shall also include for temporary shoring for the safety of portions not required to be pulled
down, or of adjoining property, and providing temporary enclosures or partitions, where considered
necessary.

DEMOLITION OF JACK ARCHES
Sub Head : Dismantling and Demolition

Clause : 15.2.4
Fig. 15.1 : Demolition of Jack Arches

DEMOLITION OF MASONRY AND BRICKWORK ARCHES

Clause : 15.2.4 and 15.2.5
Note: Order of Demolition
Fig. 15.2 : Demolition of Masonry and Brickwork Arches

HAND DEMOLITION OF IN-SITU CONCRETE STRUCTURE

Clause : 15.2.7.4
Fig. 15.3 : Hand Demolition of In-Situ Concrete Structure

SUB HEAD : 16.0
ROAD WORK
745
CONTENTS
List of Mandatory Tests 751
List of Bureau of Indian Standards Codes and 757

IRC Standards
16.1 Materials 760
16.2 Sub-Grade : Preparation and Consolidation 768
16.3 Embankment Construction (Under Optimum 769

Moisture Conditions)
16.4 Supplying and Stacking of Materials 770
16.5 Earthwork in Road Construction 772
16.6 Embankment Construction (without Optimum 772

Moisture Conditions)
16.7 Water Bound Macadam with Stone Aggregate 775
16.8 Water Bound Macadam with Brick Aggregate 778

(Overburnt (Jhama) Brick Aggregate)
16.9 Bajri Paths 779
16.10 Brick Edging 779
16.11 Scarifying Metalled (Water Bound) Surface 780
16.12 Dry Stone Pitching 780
16.13 Brick Pitching 781
16.14 Cutting W.B.M. Roads and Making Good 782
16.15 Cutting Bajri Paths and Making Good 782
16.16 Fencing with G.I. Barbed Wire and RCC Posts 783
16.17 G.I. Barbed Wire Fencing with Angle Iron Posts 783
747 SUB HEAD 16.0 : ROAD WORK

16.18 Welded Steel Wire Fabric Fencing with RCC Posts 784
16.19 Engraving Letters in Hard Stones 785
16.20 Boundary Stones (Hard Stone) 785
16.21 Precast RCC Boundary Stone 786
16.22 Kilometers Stones (Fig. 16.7) 786
16.23 Surface Dressing on New Surface with Hot Bitumen 787

of grade VG- 10 One Coat
16.24 Surface Dressing on New Surface Using Hot Bitumen of 787

grade VG - 10 Two Coats
16.25 Surface Dressing on Old Surface with Hot Bitumen of 790

grade VG - 10 confirming to IS : 73 One Coat
16.26 Surface Dressing on New Surface with Bitumen 790

Emulsion (minimum 50% bitumen content RS grade
confirming to IS : 8887) One Coat
16.27 Surface Dressing on Old Surface with Bitumen 791

Emulsion (minimum 50% bitumen content RS grade
confirming to IS : 8887) One Coat
16.28 Tack Coat of Hot Straight Run Bitumen of grade VG- 10 791
16.29 Tack Coat with Bitumen-Emulsion/ Hot bitumen of 792

grade VG- 10
16.30 Premix Carpet with Hot Bitumen of paving asphalt 793

grade VG - 10 / VG-30
16.31 Premix Carpet with Bitumen Emulsion 795
16.32 Bituminous Penetration Macadam 796
16.33 Bitumen Mastic Wearing Courses 799
16.34 Bituminous Sheet with Hot Bitumen 805
16.35 Seal Coat 806
16.36 Cement Concrete Pavement (Under Ordinary Conditions) 808
16.37 Cement Concrete Pavement Under Controlled Conditions 808
16.38 Hard Crete 818

16.39 Expansion Joint 818
16.40 Construction Procedure 818
16.41 Painting Road/ Runways Markings 819
16.42 Painting Road Surface (with Ready Mixed Road 820

Marking Paint)
16.43 Lime Fly Ash Stabilised Soil Sub Base 820
16.44 Precast Lime Fly Ash Concrete Blocks 822
16.45 Concertina Coil Fencing 822
16.46 Dense Graded Bituminous Macadam (DBM) 823
16.47 Bituminous Macadam 828
16.48 Dense Bituminous Concrete 832
16.49 Retro Reflective Sign Board 835
16.50 Retro Reflective Overhead Signage 838
16.51 Road Markings Strips 840
16.52 Kerb Channel of Cement Concrete 842
16.53 75 mm Thick Compacted Bed of Dry Brick Ballast 842
16.54 Post Delineators 843
16.55 Excavating Holes upto 0.10 cum 843
16.56 Factory Made RCC Pavement Slab 843
16.57 Factory Made Cement Concrete Interlocking 844

Paver Block
16.58 Kerb Stone (Precast) 844
16.59 G.I. Chain Link Fabric Fencing 844
16.60 Supplying and Stacking of Hard Stone (for Stone 845

Pitching)

16.61 Vacuum Dewatered Cement Concrete Pavement 845
16.62 Granular Sub-Base 845
16.63 Wet Mix Macadam (WMM) Sub-Base/Base 847
16.64 Reflective Pavement Markers (RPM) or Road Studs 851
16.65 Prime coat over granular base 853
Appendix A Bitumen Register 855
Appendix B Determination of In-Situ Density of Asphaltic Carpet 856

or Bituminous Macadam by Sand Pouring Device
Appendix C List of Minimum Equipment to be Provided in the 857

Field Testing Laboratory by the Contractor at his
own Cost
Appendix D General Guidelines Issued by NDMC 858
Fig. 16.1 Provision for Lateral Confinement of Aggregates 862
Fig. 16.2 R.C.C. Name Board without Post 863
Fig. 16.3 Sign/Name Board 864
Fig. 16.4 Boundary Stone 865
Fig. 16.5 Standard Numerals 866
Fig. 16.6 Standard Letters 867
Fig. 16.7 Kilometre Stones Type Design 868
Fig. 16.7A Kilometre Stones Location (For Highways) 869
Fig. 16.8 Informatory Sign Board 870
Fig. 16.9 Barbed Wire Fencing (with RCC Post) 871
Fig. 16.10 Fencing with R.C.C. Post Rails, Pales 872
Fig. 16.11 Location of Informatory Sign Boards 873
Fig. 16.12 Kerb & Channel Stones 874
Fig. 16.13 Broad Details of Cooker for Bitumen Mastic in 875

Wearing Courses

LIST OF MANDATORY TESTS
Material/ Clause / Test Field/ Test Frequency of Testing
work Para No. Laboratory Procedure
1) Coarse 16.1.1 Los Angeles Abrasion IS 2386
3
Aggregate Value or Laboratory (Part 4) Per 200 m
Aggregate Impact Value
Specific gravity, Water Laboratory IS 2386
absorption & Density (Part 3)
3
Combined Flakiness Field IS 2386 Per 100 m
and (Part 1)
Elongation Indices
3
16.1.1 Size and grading of Field IS 2386 Per 100 m
Table 16.2 aggregate (Part 1)
2) Fine 16.1.2 Deleterious materials Field IS 2386 As required by the Engineer-in-
Aggregate (Part 2) Charge.
Specific gravity, Water Laboratory IS 2386

absorption & Density (Part 3)
Size and grading of Field IS 2386
aggregate (Part 1)
3) Bitumen 16.1.5 As prescribed in IS 73 or Laboratory As As required by the Engineer-in-
IRC:SP:53, IS:15462 prescribed Charge.
in IS 73
3
4) 16.3.1 (a) Moisture content Laboratory IS 2720 250 m
Embankment (Part 2)
3
under (b) Density Field IS 2720 250 m
(O.M.C. (Part 28)
conditions)
16.3.4.4 c) Control test on borrow
pits.
3
Laboratory IS 2720 One to two tests per 8000 m
(i) Gradation (Part 4)
Laboratory IS 2720 -do-
(ii) Plasticity (Part 5)
Laboratory IS 2720 -do-
(iii) Proctor Test (Part 8)
Laboratory IS 2386 As required by the Engineer-in-
(iv) Deleterious content (Part 2) Charge
3
Laboratory IS 2720 250 m
(v) Moisture contents (Part 2)
5) Prime (i) Quality of Binder Laboratory IS:73 Number of samples per lot and
Coat / Tack tests as per IS:73, IS:217 and
Coat / Fog IS:8887 as applicable
Spray
(ii) Binder temperature Field At regular close intervals
for application
(iii) Rate of spread of Field Three tests per day

Binder
6) Seal Coat Laboratory IS:73 Same as mentioned under Serial

(i) Quality of binder
/ Surface No. 5
Dressing
Laboratory IS:2386 One test per 200 cu.m of each
(ii) Aggregate Impact
(Part 4) source and whenever there is
Value or Los Angeles
change in the quality of
Abrasion Value
aggregate
(iii) Combined Flakiness Field IS:2386 One test per 100 cu.m of
Index and Elongation (Part 1) aggregate for each source and
Indices whenever there is change in the
quality of aggregate
(iv) Stripping value of Laboratory IS:6241 One test of each source and
aggregates (Immersion whenever there is change in the
Tray Test) quality of aggregate
(v) Water absorption of Laboratory IS:2386 -- do --

(v) Water absorption of Laboratory IS:2386 -- do --
aggregates (Part 3)
(vi) Grading of Field IS:2386 Two tests per day
aggregates (Part 1)
(vii) Soundness test Laboratory IS:2386 One test for each source and
(Magnesium and Sodium (Part 5) whenever there is change in the
Sulphate) quality of aggregate
(viii) Temperature of Field At regular intervals
binder in boiler,
aggregate in dryer and
mix at the time of laying
and compaction
(ix) Rate of spread of Field Same as mentioned under Serial
materials No. 5
(x) Percentage of Field One test per 100 cu.m of
fractured faces (When aggregate
gravel is used)
7) Bitumen 16.32 & Field IS 73 Same as mentioned under Serial
Macadam 16.47 No. 5
Laboratory IS 2386 Same as mentioned under Serial
(Part 4) No. 6
Value/ Los Angeles
Abrasion Value
(iii) Combined Flakiness Laboratory IS 2386 One test per 350 cu.m for each
Index and Elongation (Part 1) source
Indices
(iv) Stripping value of Laboratory IS 6241 Same as mentioned under Serial
aggregates No. 6
(v) Water absorption of Field or IS 2386 Same as mentioned under Serial
aggregates Laboratory (Part 3) No. 6
(vi) Deleterious material Field IS:2386 Once in the month
(Part 2)
(vii) Grading of Field IS 2386 Same as mentioned under Serial
(Part 1) No. 6
aggregates
(viii) Soundness test Laboratory IS:2386 Same as mentioned under Serial
(Magnesium and Sodium (Part 5) No. 6
Sulphate)
(ix) Binder content Laboratory Two test per day per plant
(x) Control of temperature Field Same as mentioned under Serial
of binder and aggregate for No. 6
mix and of the mix at the
time of laying and rolling
(xi) Density of Comp Laboratory IS 2386 One test per 700 sq.m area
layer (Part 3)
(xii) Rate of spread of Field At regular intervals.
Mixed materials
8) Dense Laboratory IS:73 Number of samples per lot and
Bituminous tests as per IS:73 or IRC:SP:53,
Macadam / IS:15462
Bituminous
Concrete
Laboratory IS:2386 One test per 350 cu.m of
(Part 4) aggregate for each sour and
Value / Los Angeles
whenever there is change in the
Abrasion Value
(iii) Flakiness and Laboratory IS:2386 One test per 350 cu.m of
Elongation Indices (Part 1) aggregate for each source and
whenever there is change in the
(iv) Soundness test Laboratory IS:2386 One test for each source and
(Sodium or Magnesium (Part 5) whenever there is change in the
Sulphate test) quality of aggregate
(v) Water absorption of Laboratory IS:2386 One test for each source and
aggregates (Part 3) whenever there is change in the

(vi) Plasticity Index Laboratory IS:2386 One test for each source and
(Part 5) whenever there is change in the
(vii) Mix grading Laboratory One set for individual constituent
and mixed aggregate from dryer
for each 400 tonnes of mix
subject to minimum of two tests
per day per plant
(viii) Stability and voids Laboratory Three tests for stability, flow
analysis of mix including value, density and void contents
theoretical maximum for each 400 tonnes of mix
specific of loose mix subject to minimum of two tests
per day per plant.
(ix) Moisture Laboratory One test for each mix type
Susceptibility of mix whenever there is change in the
(AASHTO T283) quality or source of coarse of fine
aggregate
(x) Temperature of Field At regular intervals
binder in boiler,
aggregate in dryer and
mix at the time of laying
and compaction
(xii) Binder content Laboratory One set for each 400 tonnes of
mix subject to minimum of two
tests per day per plant
th
(xii) Rate of spread of Field After every 5 truck load
mix material
(xiii) Density of Laboratory One test per 700 sq.m area
compacted layer
Laboratory One per source / site
(i) Quality of aggregate
sand equivalent value
water absorption
9) Slurry seal soundness test (Sodium /
and Micro Magnesium Sulphate
surfacing Test)
Laboratory One per lot of 20 t as per IS:8887
(ii) Quality of Emulsion
(iii) Aggregate Moisture Laboratory Two per day
(iv) Aggregate Field IS:2386 Two per day at site
Gradation (Part 1)
(v) Binder Content Laboratory Two per lane per Km
(vi) Calibration of Laboratory Once per Project
Machine
(vii) Quantity of Slurry (By Field Daily (Travel time of Machine)
weight of aggregate)
10) Mastic Laboratory Same as mentioned under serial
asphalt No. 8
Laboratory IS:2386 Same as mentioned under serial
(Part 4) No. 8
Value or Los Angeles
Abrasion Value
(iii) Combined Flakiness Field IS:2386 Same as mentioned under serial
and Elongation Indices (Part 1) No. 8
(iv) Stripping value Laboratory IS:6241 Same as mentioned under serial
No. 6
(v) Deleterious material Field IS:2386 One in a month
(Part 2)
(vi) Grading of Field IS:2386 Two tests per day per plant on
aggregates (Part 1) the individual constituent and
mixed aggregates from the dryer
(vii) Water absorption of Laboratory IS:2386 Same as mentioned under serial
(Part 3) No. 8
aggregates
(viii) Soundness test Laboratory IS:2386 Same as mentioned under serial
(Magnesium Sulphate / (Part 5) No. 8
Sodium Sulphate)

(ix) Binder content Laboratory Two test per day per plant
(x) Control of Field At regular close intervals
temperature of binder
and aggregate for mixing
and of the mix at the time
of laying and rolling
(xi) Rate of Spread of Field Regular control through check of
Mixed Material layer thickness
(xii) Hardness number Laboratory Minimum two tests per day
11) Recycled Grading of aggregate Field IS:2386 Two tests per day
Material (Part 1)
12) Cold Laboratory All tests as per S. No. 8
Mixes
13) Quality of Laboratory Number of samples per lot and
Modified tests as per IS:15462
Binder
Laboratory The requirements of Section 700
14) Geo of MORTH Specification shall
textiles apply
15) Granular Field IS:2386 One test per 400 cu.m.
(i) Gradation
Sub Base (Part 1)
(GSB)
Laboratory IS:2720 One test per 400 cu.m.
(ii) Atterberg limits
(Part 5)
(iii) Water absorption Laboratory One test per 400 cu.m.
(iv) Density of Laboratory One test per 1000 cu.m.
compacted layer
(v) Deleterious Field IS:2386 As required
constituents (Part 2)
(vi) Soundness test Field IS:2386 Same as mentioned under serial
(Part 5) No. 8
(vii) CBR Laboratory As required
16) Lime / Laboratory One test for each consignment
(i) Quality of lime /
Cement subject to a minimum of one test
Stabilised Cement
per 5 tonnes
Soil Sub-base
Laboratory Regularly, through procedural
(ii) Lime / Cement
checks
content
(iii) Degree of Laboratory Periodically as considered
pulverization necessary
(iv) CBR or Unconfined Laboratory As required
Compressive Strength
Test on a set of 3
specimens
(v) Moisture content Laboratory One set of two tests per 500
prior to compaction sq.m.
(vi) Density of Laboratory One set of two tests per 500
compacted layer sq.m.
(vii) Deleterious Field As required
constituents
17) Water Laboratory IS:2386 One tests per 1000 cu.m of
(i) Aggregate Impact
Bound (Part 4) aggregate
Macadam Value
Field IS:2386 One test per 250 cu.m
(ii) Grading of aggregate
(Part 1)
(iii) Combined Flakiness Laboratory IS:2386 One tests per 500 cu.m of
and Elongation Indices (Part 1) aggregate
(iv) Atterberg limits of Laboratory IS:2386 One test per 50 cu.m of binding
binding material (Part 4) material
(v) Atterberg limits of Laboratory IS:2720 One tests per 100 cu.m of
screenings (Part 5) aggregate
(vi) Water absorption of Laboratory IS:2386 Once in a month
aggregate (Part 3)
(vii) Deleterious material Field IS:2386 As required, once in a month

(Part 2)

18) Wet Mix Laboratory IS:2386 One tests per 1000 cu.m of
(i) Aggregate Impact
(Part 4) aggregate
Macadam Value or Los Angeles
Abrasion value
Field IS:2386 One tests per 200 cu.m of
(ii) Grading of aggregate
(Part 1) aggregate
(iii) Combined Flakiness Laboratory IS:2386 One tests per 500 cu.m of
and Elongation Indices (Part 1) aggregate
(iv) Atterberg limits of Laboratory IS:2720 One tests per 200 cu.m of
portion of aggregate (Part 5) aggregate
passing 425 micron
sieve
(v) Density of Field One set of three tests per 1000
compacted layer sq.m.
(vi) Water absorption of Laboratory IS:2386 Once in a month
aggregate (Part 3)
(vii) Deleterious material Field IS:2386 As required, once in a month

(Part 2)
19) Cement 16.37.19 Coarse aggregate Laboratory IS 2386 Before approval of
concrete 1. Flakiness Index (Part 1) the quarry and every sub-
pavement sequent change in the source of
under supply and one test per 100 cum.
controlled
conditions
2. Impact Value -do- IS 2386 -do-
(Part 4)
3. Loss Angles abrasion -do- -do- -do-
Value
4. Deleterious material -do- IS 2386 Before approval of
(Part 2) the quarry and at
every subsequent
change in the source of supply
5. Moisture content -do- IS 2386 Regularly as required subject to
(Part 3) a minimum of one test per day
Fine Aggregate
1. Silt content Field As per One test per 15 cum.
CPWD
specification
Vol. I.
2. Gradation of sand -do- IS 2386 -do-
(Part 2)
3. Deleterious material -do- IS 2386 Before approval of the quarry
(Part 2) and at every subsequent change
in the source of supply
4. Moisture content -do- IS 2386 Regularly as required subject to
(Part 3) a minimum of two tests per day
5. Mix Aggregate Field IS 2386 One test per 15 cum of concrete
(Part 1)
6. Flextural strength Laboratory IS 526 One test consisting
of 8 specimen for 30 cum. of
concrete

LIST OF BUREAU OF INDIAN STANDARDS CODES AND IRC STANDARDS

1. IS 73 Specification for paving bitumen
2. IS 164 Ready mixed paint for road marking
3. IS 217 Specification for cut back bitumen
4. IS 8112 Specification for 43 grade ordinary Portland Cement
5. IS 278 Specification for galvanized steel barbed wire for fencing
6. IS 334 Glossary of terms relating to bitumen and tar
7. IS 383 Specification for coarse and fine aggregate from natural sources
for concrete
8. IS 460 Specification for test sieves
9. IS 516 Method of test for strength of concrete
10. IS 702 Specification for industrial bitumen
11. IS 712 Specification for building limes
12. IS 1195 Specification for bitumen mastic for flooring
13. IS 1199 Methods of sampling and analysis of concrete
14. IS 1203 Method of testing tar and bituminous material, determination of
penetration
15. IS 1205 Method of testing tar and bituminous material determination of
softening paint
ductility
17. IS 1212 Method of testing tar and bituminous material determination of loss
of heating
solubility in carbon-di-sulphide, trichloroethylene
19. IS 1834 Specification for hot applied sealing compound for joint in concrete
20. IS 1838 (Pt. 1) Specification for performed fillers for expansion joint in concrete
pavements and structures (non extruding and resilient type/ bitumen
impregnated fibre)
21. IS 2386 (Pt. 1) Method of test for aggregate for concrete particle size and shape
22. IS 2386 (Pt. 2) 1963 Method of test for aggregate for concrete estimation of deleterious
materials and organic impurities
23. IS 2386 (Pt. 3) Method of test for aggregate for concrete specific gravity, density,
voids, absorption and bulking
24. IS 2386 (Pt. 4) Method of test for aggregate for concrete mechanical properties

25. IS 2720 (Pt.V) Method of test for soil: Determination of liquid and plastic limit.
26. IS 2720 (Pt. VII) Methods of test for soils: part VII determination of water content
dry density relation using light compaction
27. IS 2720 (Pt. XXVIII) Method of test for soil: determination of dry density of soils in place,
by sand replacement method
28. IS 3812 Specification for fly ash for use as pozzolana and admixture
29. IS 5317 Specification for bitumen mastic for bridges decking and roads
30. IS 5640 Method of test for determining aggregate impact value of soft coarse
aggregates
31. IS 6241 Method of test for determination of stripping value of road
aggregates

IRC STANDARDS:
1. IRC 10 Recommended practice for borrow pits for road embankments

constructed by manual operation
2. IRC 29 Specification for bituminous concrete for road pavements
3. IRC 36 Recommended practice for construction of earth embankments
for road works
4. IRC 60 Tentative guidelines for the use of lime flyash concrete as pavement
base of sub base
5. IRC 88 Recommended practice for lime flyash stabilized soil base/ sub
base in pavement construction
6. IRC 107 Tentative specification for bitumen mastic wearing courses

16.0 ROAD WORK
16.0 TERMINOLOGY
Asphalt : A natural or artificial mixture in which bitumen is associated with mineral matter. The word ‘Asphalt’
should always be qualified by indication of its origin or nature.
Asphalt Mastic : An intimate mixture of mineral fillers, well graded sand and/or stone chippings with a hard
grade of bitumen, cooked and laid hot manually by means of wooden float. The mixture settles to a coherent,
void less and impermeable solid or semi-solid mass under normal temperature condition.
Binder: The binder shall be an appropriate type of bituminous materials complying with the relevant Indian
Standard (IS) as defined in the appropriate clauses of these specifications or as otherwise specified herein.
The choice of binder shall be stipulated in the contract or by the Engineer-in-charge.
Bitumen: A black or dark brown non crystalline solid or viscous material, having adhesive properties derived
from petroleum either by natural or refinery processes and substantially soluble in carbon disulphide.
Bitumen shall be paving bitumen of viscosity grade complying with Indian Standard Specifications for “Paving
bitumen” IS:73:2006 of grade appropriate for the traffic and climatic conditions of the Project Highway. The heavily
trafficked roads in hot areas may find harder grade bitumen more appropriate while pavements in mountainous
regions subject to sub-zero temperatures during winter months carrying relatively lower traffic loads subject to the
phenomenon of “Frost Heave” may find less viscous bitumen resistant to fatigue and cold cracking more appropriate.
Bitumen-Cutback : Bitumen, the viscosity of which has been reduced by a volatile dilutent when blended
with kerosene or naptha type dilutent or fuel oil, is called, medium or rapid or slow curing cut backs respectively.
Bitumen-Emulsion : A liquid product in which a substantial amount of bitumen is suspended in a finely
divided condition in an aqueous medium containing an emulsifier and stabiliser. The emulsion is termed
‘Anionic’ when the bitumen particles are negatively charged and the aqueous phase is alkaline. The emulsion
is termed ‘cationic’ when the particles are positively charged and the aqueous phase is acidic.
Bitumen Mastic Filler : Inorganic mineral material all of which will pass through specified IS sieve used in
admixture with solid or semi-solid bituminous material.
Road tar : A product obtained by treating at high temperature coal tar in such a manner that it conforms to a
specification which defines its suitability for road construction.
Tar : A viscous material having adhesive properties and resulting from the distinctive distilation of certain type
of organic material. The term Tar should be preceded by the name of the material from which it is produced
e.g. coal, shale, peat, vegetable matter and its mode of production shall be indicated.
Flash point : The lowest temperature at which the vapour of a substance can be ignited in air by a flame under
specified conditions of test. The substance itself does not continue to burn.
Tack Coat : It shall consist of application of a single coat of low viscosity liquid bituminous material to an
existing road surface preparatory to further bituminous construction.
Bitumen concrete (Asphaltic concrete) : A well graded mixture of high quality aggregates with designated
proposition of bitumen, hot mixed, hot laid and hot rolled into a uniform dense mass with specified design criteria.
Ductility : The property by which a material can be drawn out without breaking, for bitumen it is measured by the
distance in centimetres to which it will elongate before breaking, when two ends of a briquette specimen of the
material of the specified form and cross- section are pulled apart under water at a specified speed and temperature.
Viscosity : The property of a liquid by which it resists flow due to internal friction and is measured by the ratio
of the shearing stress to the rate of shear.
16.1 MATERIALS
16.1.1 Aggregate Coarse
Coarse aggregate as specified in the item shall be either crushed/broken stone, crushed slag, over burnt
(Jhama) brick aggregate or one of the naturally occuring aggregates such as kanker or laterite of suitable
quality as stated hereinafter and approved by the Engineer-in-Charge.
The stone aggregate shall confirm to the physical requirements set forth in Table 16.1. The type and size
range of the aggregate shall be specified in the contract.

If the water absorption value of the coarse aggregate is greater than 2 percent, the soundness
test shall be carried out on the material delivered to side as per IS:2386 (Part-5).
TABLE 16.1
Physical Requirements of Coarse Aggregate for Water Bound Macadam for
Sub-Base / Base Courses
S. No Test Test method Requirements
1.*** Los Angeles Abrasion value IS 2386 (Part-4) 40% (Max.)
or IS 2386 (Part-4) or 30% (Max.)
Aggregate impact value IS 5640*
2. Combined flakiness and IS 2386 (Part-1) 35% (Max.)
Elongation Indices (Total)**
* Aggregates which get softened in presence of water shall be tested for impact value under wet
conditions in accordance with IS:5640.
** The requirements of flakiness index and elongation index shall be enforced only in case of
crushed/broken stone and crushed slag.
*** In case water bound macadam is used for sub-base, the requirements in respect of Los Angeles
Value and Aggregate Impact Value shall be relaxed to 50 percent and 40 percent maximum
respectively.
The coarse aggregate shall conform to one of the gradings given in Table 16.2 as specified. For
crushable type of aggregates such as brick metal, kankar and laterite, grading shall not be regarded
as very important, but the material should generally be within the specified range.
TABLE 16.2
Grading Requirements of Coarse Aggregate for W.B.M.
Grading No. Size Range IS Sieve Designation Percent by weight

passing the sieve
1 90 mm to 45 mm 125 mm 100
90 mm 90 – 100
63 mm 25 – 60
45 mm 0 – 15
22.4 mm 0–5
2 63 mm to 45 mm 90 mm 100
63 mm 90 – 100
53 mm 25 - 75
45 mm 0 – 15
22.4 mm 0–5
3 53 mm to 22.4 mm 63 mm 100
53 mm 95 – 100
45 mm 65 – 90
22.4 mm 0 – 10
11.2 mm 0-5
Note: The compact thickness for a layer with Grading 1 shall be 100 mm while for layer with
other Gradings i.e. 2 & 3, it shall be 75 mm.

16.1.1.1 Overburnt (Jhama) Brick Aggregates: Brick aggregate shall be made from over-burnt
bricks and dense brick bats. It shall be homogeneous in texture, roughly cubical in shape, clean and
free from dust, dirt and other objectionable and deleterious materials.
16.1.1.2 Crushed or Broken Stone : When crushed or broken stone is specified as the coarse
aggregate, it shall be hard, durable and free from excess of flat, elongated, soft, disintegrated particles,
dirt and other objectionable matter. The total quantity of such deleterious material including clay
lumps, soft fragment, foreign material etc. shall not exceed 5% of the weight of the aggregate.
16.1.1.3 Crushed Slag : Crushed slag shall be made from air-cooled blast furnace slag. It shall be of
angular shape, reasonably uniform in quality and density and generally free from thin, elongated
and soft pieces, dirt or other deleterious materials. The weight of the crushed slag shall not be less
than 11.2 kN per cubic metre (1120 kg per cubic metre) and the percentage of glossy material shall
not be more then 20. Water absorption of slag shall not exceed 10% (IS 2386 Pt.III).
16.1.1.4 Kankar : Kankar shall be tough, having a blue almost opalescent fracture. It shall not
contain any clay in the cavities between nodules.
16.1.1.5 Laterite : Laterite shall be hard, compact, heavy and of dark colour. The light coloured
sandy laterite as well as those containing much ochreous clay shall be rejected.
16.1.2 Aggregate-Fine
The fine aggregate shall be the fraction passing 2.8 mm sieve and retained on 90 micron sieve. It
shall consist of crusher run screenings, natural sand or a mixture of both. These shall be clean,
hard, durable, uncoated, dry and free from injurious, soft or flaky pieces and organic or deleterious
substance.
The contents of organic and deleterious materials shall not exceed the limits specified in Table 16.3.
TABLE 16.3
Uncrushed Crushed
Coal and lignite 1% 1%
Clay lumps 1% 1%
Material passing through 75 microns (I.S.S.) Sieve 3% 3%
Shale 1% 1%
The sum of the percentages of all deleterious material shall not exceed 5%. Tests for estimation of
deleterious materials and organic impurities shall be done as per IS 2386 (Pt. II).
16.1.3 G.I. Barbed Wire

The barbed wire shall be of galvanised steel as specified and it shall conform to IS 278. The
sampling criteria is given in Table 16.4. The wire shall be manufactured from steel by any process
and shall not contain sulphur and phosphorous exceeding 0.065 per cent. The galvanised steel
barbed wires shall be of two types: Type A (Lowa Type) and Type B (Glidden Type).
Type A (Lowa Type) : The barbs shall have four points and shall be formed by twisting two point
wires, each two turns, tightly around both line wires making altogether four complete turns.
Type B (Glidden Type) : The barbs shall have four points and shall be formed by twisting two
point wires, each two turns, tightly around one line wire making altogether four complete turns.
Details of G.I. Barbed wire

The galvanised steel barbed wire shall be of the size designations given in Table 16.4.

TABLE 16.4
Size Nominal dia. of wire Mass of Distance No. of lays
Designatio Line Wire Point Wire completed between between
n Barbed Wire two barbs the two
Nom Tol Nom Tol Max Min consecutiv
e barbs
(mm) (mm) (mm) (mm) (g/m) (g/m) (mm) (mm)
2.5 2 to
1. 2.50 ± 0.08 0 ± 0.08 155 136 75 ± 12 7
2.5 2 to
2. 2.50 ± 0.08 0 ± 0.08 120 108 150 ± 12 7
2.0 2 to
3. 2.50 ± 0.08 0 ± 0.08 125 108 75 ± 12 7
2.0 2 to
4. 2.50 ± 0.08 0 ± 0.08 103 89 150 ± 12 7
2.0 2 to
5. 2.24 ± 0.08 0 ± 0.08 106 97 75 ± 12 7
2.0 2 to
6. 2.24 ± 0.08 0 ± 0.08 85 78 150 ± 12 7
Note : The mass in g/m shall be obtained by dividing the total mass of the reel by the linear length
in metres.
The number of lays between the two consecutive barbs shall very between 2 to 7.
The barbed wire shall be formed by twisting together two line wires, one or both containing the
barbs. The size of the line and point wires and barb spacings shall be as specified. The permissible
deviation from the nominal diameter of the line wire and the point wire shall not exceed + 0.08 mm.
The line and point wires shall be circular in section, free from scales and other defects and shall be
uniformly galvanised. The line wire, shall be in continuous lengths, and shall not contain any welds
other than those in the rod before it is drawn. The distance between two successive splices shall not
be less than 15 metres. It shall have the tensile properties as specified in Table 16.5.
TABLE 16.5
Tensile Properties
Size of Line Minimum Breaking Load of Completed Barbed
Wire Tensile Strength of line wire Wire
mm kgf/sq. mm kgf
2.50 40 to 60 375
2.24 40 to 60 300
The number of reels to be selected at random for this purpose shall be in accordance with Table 16.6.
TABLE 16.6
Sampling Criteria
No. of Reels in the Lot No. of Reels to be selected
Up to 25 3
26 to 50 4
51 to 150 5
151 to 300 7
301 and above 10

16.1.4 Binding Material
Binding materials to prevent ravelling of water bound macadam construction shall consist of a
fine grained material possessing plasticity index value of 4 to 9 when the water bound macadam is to
be used as a wearing course, and 4 to 6 when W.B.M. is being adopted as a sub-base/base course
with bitumious surfacing on top of it. The plasticity index shall be determined in accordance with IS
2720 (Pt. V). The quantity of binding material used in each layer shall be as per direction of Engineer-
in-Charge. Application of binding material may be dispensed with the approval of Engineer-in-Charge,
where screenings consisting of crushable type material like moorum or gravel are used. Where earth
cut for sub-grade formation is used as binder with the approval of Engineer-in-Charge, no separate
payment shall be made for collection of this binder material.
16.1.5 Bitumen Straight Run

A range of grades, from a very soft to a very hard consistency, can be produced by varying the
tem-perature and the rate of flow during distilling process. It shall conform to IS 73. Grades of bitumen
for different uses is given in Table 16.7.
TABLE 16.7
Bitumen Grades
Grade Temperature to which it shall be heated

I. FOR PAINTING (Surface Dressing)
1. Paving bitumen of grade VG- 10 177 deg. C to 190 deg. C
2. Paving bitumen of grade VG- 30 177 deg C to 190 deg. C
3. Bitumen emulsion min. 50% bitumen content:- RS
grade IS 8837 (Cold application)
4. Cut backs RC-3 (rapid curing) IS 217 —do—
II. FOR PREMIX CARPETING

1. Paving asphalt 30/40 S-35 or 80/100 S-90 149 deg. C to 177 deg. C
2. Bitumen Emulsion min. 60% bitumen contents RS
grade IS 8837 (Cold application)
3. Cut back MC (medium curing) IS 4545 (Cold application)
III. FOR ASPHALTIC CONCRETE STRAIGHT RUN 150 deg. C to 177 deg. C
BITUMEN 60/70 (S-65) CONFORMING TO IS 73
Note : For premix carpeting with paving asphalt, extra shall be paid if solvent is used.
16.1.6 Bricks
Bricks shall be of class designation 75 unless otherwise stated. The specifications of bricks shall
be as sub head brick work as detailed in subhead 6.0 Vol – I, CPWD Specification – 2019.
16.1.7 Filler
The filler, where specified, shall be an inert material, the whole of which passes through a 710
micron sieve, atleast 90 per cent passing through a 180 micron sieve and not less than 70 per cent
passing through a 90 micron sieve. The filler shall be cement, stone dust, hydrated lime, lime stone
dust, flyash or any other non-plastic mineral matter approved by the Engineer-in-Charge.

TABLE 16.8
Aggregate Gradation including Filler
Sieve designation Percent by weight passing the sieve
For 25 mm thickness For 20 mm thickness
20.0 mm 100 -
12.5 mm 75-100 100
10.0 mm 60-85 75 – 100
4.75 mm 35-55 35 – 55
2.36 mm 20-35 20 – 35
600 micron 10-22 10 – 22
300 micron 6-16 6 – 16
150 micron 4-12 4 – 12
75 micron 2- 8 2-8
16.1.8 Flyash
Flyash shall conform to IS 3812
16.1.9 Lime
Lime shall be of specifications as directed by Engineer-in-Charge.
16.1.10 Moorum
It shall be obtained from pits of weathered disintegrated rocks. It should preferably contain silicious
material and natural mixture of clay of calcarious origin. The size of moorum shall not be more than
20 mm.
16.1.11 Posts, Rails and Pales

These shall be of standard size and length of posts being 1.8 m, rails 2.25 m and pales 1.25 m
unless otherwise specified. A tolerance of 12 mm in length and 3 mm in other dimensions shall be
permissible. These shall be cast in cement concrete 1:1 ½ 3 (1 cement : 1 ½ coarse sand : 3 graded
stone aggregate 12.5 mm nominal size) with slots and reinforced with tor steel bars of diameters 10
mm in the case of posts and pales and 8 mm in the case of rails or as directed and finished with
cement mortar 1:2 (1 cement :2 fine sand). The specifications for R. C. C. work shall apply.
For the whole of their length below the top of the rail the paling shall have a projecting dovetail
shape at the back which shall fit into dovetail grooves in each of the rails. That part of the palings
projecting above the top rail shall be left square to prevent the dropping right through the rails. The
posts, rails and pales shall be free from cracks, twists and such other defects.
16.1.12 Posts and Struts—R.C.C.

All posts and struts shall be of standard size, the length of posts being 1.8 m or as specified and
that of struts being minimum of 2.0 m. These shall be cast in cement concrete 1:1 ½ :3 (1 cement :
1 ½ coarse sand : 3 graded stone aggregate 12.5 mm nominal size) reinforced with 10 mm diameter
tor steel bars as directed and finished smooth with cement mortar 1:2 (1 cement: 2 fine sand). The
specifications for R.C.C. work shall apply. The posts and struts shall be free from cracks, twists and
such other defects. G.I. staples on wooden plugs or 6 mm bar nibs will be provided as directed by
Engineer-in-Charge while casting the posts. Quantity of RCC post, struts, Rails and Pales to be
measured in cubic content.
16.1.13 Premoulded Joint Filler

It shall conform to IS 1838, the thickness shall be 20 mm or 25 mm as specified and shall be of
the maximum available standard length. During the casting of the slab the premoulded joint filler
shall be placed accurately in position against the finished end of concrete slab. The filler shall
remain 20 mm below the top surface of the pavement and shall extend upto the subgrade.

16.1.14 Red Bajri
This shall be disintegrated rock dark red in colour consisting of coarse grains, free from mica, dust and
other foreign matter.
16.1.15 Screenings
Screening to fill voids in the coarse aggregate shall generally consists of the same material as the coarse
aggregate. However, where permitted, predominantly non-plastic material such as moorum or gravel (other than
river borne rounded material) may be used for this purpose provided liquid limit and plasticity index of such
material is below 20 and 6 respectively and fraction passing 75 micron sieve does not exceed 10 percent.
As far as possible screenings shall conform to the gradings set-forth in Table 16.9. Screenings of type A
shall be used with coarse aggregate of grade I of Table 16.2. Screenings of type A or B as specified shall be
used with coarse aggregates of grading 2. Type B screenings shall be used with coarse aggregates of grading
3. The use of screenings may be omitted in the case of soft aggregates such as brick metal, kankar and
laterite. For screenings like moorum or gravel the gradings given in Table 16.9 shall not be binding.
TABLE 16.9
Grading for Screenings
Grading
Size of Screenings IS Sieve Designation Percent by Weight Passing Sieve
Classification
A 13.2 mm 13.2 mm 100
11.2 mm 95 -100
5.6 mm 15 - 35
180 micron 0 – 10
B 11.2 mm 11.2 mm 100
9.5 mm 80-100
5.6 mm 50 - 70
180 micron 05 - 25
16.1.16 Sealing Compound
After the curing period is over the joint portion above the filler board shall be cleaned thoroughly as
directed by the Engineer-in-Charge. The joints shall be filled with hot applied sealing compound. Grade A
(Normal) for concrete constructions other than those which are subjected to spillage of kerosene or other
heavy petroleum oils and Grade B (Jet fuel resistant) for concrete constructions of runways for jet air crafts,
conforming to IS 1834.
16.1.17 Soil
Soil having a plasticity index (PI) between 5 and 20 shall be suitable. Atleast one test for 200 cubic metre
of soil for determining P.I. shall be conducted.
16.1.18 Stones
These shall be clean, hard, sound and durable stones, free from decay and weathering. They shall be in
blocks and hammer dressed on all sides. The size of pitching stones shall be approximately 22.5 cm in depth
and not less than 15 cm in any other direction.
16.1.19 Stone Chippings For Surface Dressing/Painting

The stone chipping shall consist of fairly cubical fragment of clean, hard, tough and durable rock of
uniform quality throughout. These shall be obtained by crushing stone river gravel (shingle) or other approved
materials. Rounded gravel shall be used only if specifically permitted by the Engineer-in-Charge. The chipping
shall be free of elongated or falky pieces, soft or disintegrated stone, salt, alkali, vegetable matter, dust and
adherant coatings. They shall conform to the quality requirements of Table 16.10.
However, the total quantity of such deleterious material including clay lumps, soft fragments, foreign
material shall not exceed 5% of the weight of the aggregate.
The aggregate shall be got tested to ensure the requirements specified in Table 16.10.

TABLE 16.10
Physical Requirements of Aggregates for Surface Dressing
Sl. No. Test Test method Requirements
1. Los Angles Abrasion Value IS 2386 (Part-4) 40% (Max.)
2. Aggregate Impact Value* IS 2386 (Part-4) 30% (Max.)
3. Flakiness Index IS 2386 (Part-1) 25% (Max.)
4. Stripping Value IS 6241 25% (Max.)
5. Water Absorption IS 2386 (Part-3) 1% (Max.)
* Aggregates may satisfy requirements of either of the two tests.
16.1.20 Stones for Kerb and Channels (Fig. 16.12)

Kerb and channel stones are provided on roads having raised berms for foot path etc. These shall be of
selected hard stone, sound, durable free from laminations and other structural defects. The length of each
kerb and channel stone shall be not less than 49.5 cm except that 29.5 cm long stones shall be permitted for
closures and for curves. The other dimensions shall be 30 x 20 cm for kerb stones and 30 x 10 cm for channel
stones, unless specified otherwise. Kerb and channel stones shall be chisel dressed on exposed surface and
edges. The dimensions of the exposed faces of kerb and channel stones shall be of sizes as specified with a
tolerance of 10 mm in width and depth. In the case of kerb stones a tolerance of 5 cm shall be allowed in the
dimensions of unexposed back and bottom faces and in the case of channel stones a tolerance of 10 mm
shall be allowed in thickness.
16.1.21 Boundary Stone (Fig. 16.4 )

The boundary stones shall be of either hard stone or sound and durable quality or precast R.C.C. These
shall be in blocks of size 15 × 15 × 90 cm unless directed otherwise by the Engineer-in-Charge. A tolerance
of 12.5 mm shall be permitted in the specified size. In the case of boundary stones of hard stone, the upper
30 cm shall be chiesel dressed on all the four sides and on the top.
The R.C.C. boundary stones shall be cast in cement concrete 1 : 1 ½ : 3 (1 cement : 1 ½ coarse sand :
3 graded stone aggregate 20 mm nominal size), reinforced with 10 mm diameter tor steel bars or as directed
and finished smooth with cement mortar 1 : 3 (1 cement : 3 fine sand ). The specifications for R.C.C. work
shall apply.
16.1.22 Kilometer stone (Fig.16.7)

Standard design of kilometer stones are given in Fig. 16.7. Ordinary kilometer stone for National Highways,
State highways and Major District shall be of the size 35 × 111 × 25 cm. One cm offset shall be provided
around the stone slab in 10 cm height above the formation level to serve as the pedestal. The kilometer stones
shall be fixed at right angle to the centre line of the carriage way. The kilometre stone shall indicate the name
and distance of the next (intermediate) important town only. On the side of the kilometre stone facing the
carriage way, the number of the kilometre stone shall be inscribed (without the name of any place) which shall
be painted later on.
Kilometre stones for every fifth kilometre on National Highways, State highways and major district roads
shall be of the size 50 x 152.5 x 25 cm. One cm offset shall be provided around the stone slab in 13 cm height
above the formation level to serve as the pedestal. This kilometre stone shall be fixed at right angles to the centre
line of carriage way. It shall show the name and distance of the terminal or the starting station also above those
of intermediate towns. On the side facing the carriage way, the number of the kilometre stone in continuity of
ordinary kilometre stone shall be inscribed (without the name of any place) which shall be painted later on.
Kilometre stone for other district roads and village roads shall be of the size 35 × 93.5 × 18 cm. One cm
offset shall be provided around the stone slab in 10 cm. height above the formation level to serve as the
pedestal. It shall be fixed at right angles to the centre line of carriage way and shall indicate the name and the
distance of the next important station. On the side facing the carriage way, the number of the kilometre stone
shall be inscribed (without the name of any place).

The kilometre stones shall be fixed at the edge of the road way outside the shoulder on especially
erected platforms, if necessary. In cutting these shall be fixed clear of the shoulder and the side drain
as per Fig. 16.7(A). On existing roads the stones shall be fixed on the side of the road other than that
on which miles stones exist. On new roads, these shall be located on left hand side of the road as
one proceeds from the station from which kilometre count starts.
Kilometre stones shall be of approved design of R.C.C. or stone slabs.

(a) Kilometre Stones in R.C.C. : It shall be cast in cement concrete 1:2:4 (1 cement : 2 coarse
sand : 4 graded stone aggregate 20 mm nominal size) with reinforcement as directed and
finished smooth with cement mortar 1 : 3 (1 cement : 3 fine sand) on exposed surfaces
above the ground. The specifications for R.C.C. work shall apply.
(b) Kilometre Stone Slabs : The stone slabs shall be of red or white sand stone unless otherwise
specified. The slab shall be hard, even, sound and durable. The stone slabs shall have
been sawn or chiseled in a plane parallel to the natural bed of the stone. The slabs shall be
chisel dressed on the exposed surfaces above ground facing road side, so that the dressed
face shall not be more than 3 mm from a straight edge placed on it. The thickness of the slab
shall be uniform and as specified in the item with a permissible tolerance of 1.5 mm. The
thickness shall be measured correct to 3 mm.
16.2 SUB-GRADE : PREPARATION AND CONSOLIDATION

16.2.0 In sub-grade composed of clay, fine sand or other soils that may be forced up into the coarse
aggregate during rolling operation, an insulation layer of suitable thickness of granular materials or
over size brick aggregate not less than 10 cm thick shall be provided for blanketting the sub-grade,
which shall be paid for separately, unless otherwise specified in the agreement.
In slushy soils or in areas that are water logged, special arrangements shall be made to improve
the sub-grade and the total pavement thickness shall be designed after testing the properties of the
sub-grade soil. Necessary provision for the special treatment required shall be made in the project
and paid for separately.
16.2.1 Preparation of Sub-Grade

The surface of the formation for a width of sub-base, which shall be 15 cm more on either side of
base course, shall first be cut to a depth equal to the combined depth of sub-base and surface
courses below the proposed finished level (due allowance being made for consolidation). It shall
then be cleaned of all foreign substances. Any ruts or soft yielding patches that appear due to
improper drainage conditions, traffic hauling or from any other cause, shall be corrected and the
sub-grade dressed off parallel to the finished profile.
16.2.2 Consolidation
The sub- grade shall be consolidated with a power road roller of 8 to 12 tonnes. The roller shall
run over the sub grade till the soil is evenly and densely consolidated and behaves as an elastic
mass (the roller shall pass a minimum of 5 runs on the sub grade). All undulations in the surface that
develop due to rolling shall be made good with material or quarry spoils as the cases may be and the
sub-grade is rerolled.
16.2.3 Surface Regularity

The finished surface shall be uniform and conform to the lines, grades and typical cross section
shown in the drawings, when tested with the template and straight edge, the variation shall be within
the tolerances specified in Table 16.11.

TABLE 16.11
Permissible Tolerances of Surface Evenness of Sub Grade
Longitudinal profile maximum permissible Cross profile maximum permissible variation from
undulation when measured with a 3 metre specified profile when measured with a camber
straight edge template
24 mm 15 mm
Where the surface irregularity of the sub grade falls outside the specified tolerances, the contractor
shall be liable to rectify these with fresh material or quarry spoils as the case may be, and the sub-
grade rerolled to the satisfaction of Engineer-in-Charge.
16.2.4 Measurements
The lengh and width shall be measured correct to a cm. The area shall be worked out in square
metre, correct to two places of decimal.
16.2.5 Rate
The rate for preparation and consolidation of sub grade shall include the cost of materials and
labour involved for all the operations mentioned in above unless otherwise specified.
16.3 EMBANKMENT CONSTRUCTION (UNDER OPTIMUM MOISTURE CONDITIONS)

16.3.1 In the case of earth work consolidated under optimum moisture conditions each layer of earth
shall be carefully moistened to give field moisture content of about +1% to -2% of the optimum
moisture content (OMC). The OMC shall be determined according to IS 2720 (Pt.VIII) Methods of
Tests for Soils. Each layer shall then be compacted by rolling with 8 to 10 tonnes power road roller
and a sheep foot roller if required. The required amount of water shall be added during consolidation
to keep the moisture content of the soil at the optimum as per test. The density to be achieved for
each layer of the material shall not be less than 95% of the density obtained in the laboratory
(Proctor Method).
16. 3.2 Each compacted layer shall be tested in the field for density and accepted before the operations
for next layer are begun.
16.3.3 Control on compaction in the field shall be exercised through frequent moisture content and
density determinations. A systematic record of these shall be maintained. At all times during construction
the top of the embankment shall be maintained at such cross fall as will shed water and prevent ponding.
16.3.4 Density Measurement and Acceptance Criteria

16.3.4.1 One measurement of density shall be made for each 500 sqm of compacted area or for a
smaller area as decided by the Engineer-in-Charge. Each measurement shall consist of atleast 5
density determinations tests and the average of these 5 determinations shall be treated as the field
density achieved. The determination of density shall be as per IS 2720 (Pt. XXVIII).
16.3.4.2 In general the control at the top 40 cm thickness of the formation shall be more strict with
density measurements being done at the rate of one measurement for 250 sqm of compacted area.
Further for the determination of the mean density the number of tests in one measurement shall not
be less than 10 and the work will be accepted if the mean dry density equals or exceeds the specified
density.
16.3.4.3 When density measurements reveal any soft areas in the embankment, the Engineer-in-
Charge shall direct that these be compacted further. If in-spite of that the specified compaction is not
achieved the material in the soft areas shall be removed and replaced by approved materials and
compacted to the satisfaction of the Engineer-in-Charge.

16.3.4.4 Control Tests on Borrow Material
16.3.4.5 Soil suitable for consolidation under O.M.C. conditions should preferably have the following
characteristics :
(a) Minimum percentage of clay 10%
(b) Liquid limit 14
(c) Plasticity index 4
(d) Percentage of silt should not exceed 50%
(e) Peat, muck and organic soils are unsuitable.
16.3.4.6 The Engineer-in-Charge may, however, relax these requirements taking into account availability of
materials, cost of transportation and other relevant factors.
16.3.4.7 Various test required to be conducted on the borrow material with their recommended frequency are
indicated below. All the test need not be stipulated on every project. Depending upon site condition etc. only
some may be found necessary at a particular project. The frequency of testing indicated refers generally to
the minimum number of tests to be conducted. The rate of testing must be stepped up as found necessary
depending upon the variability of the materials and compaction methods employed at a project.
(a) Gradation : At least one test for each kind of soil. Usual rate of testing 1 to 2 tests per 8000 cum of
soil.
(b) Plasticity : At least one test for each kind of soil. Usual rate of testing 1 to 2 tests per 8000 cum of
soil.
(c) Proctor Tests : At the rate of 1 to 2 tests per 8000 cum of soil.
(d) Deleterious Contents : As required.
(e) Moisture contents : One test for every 250 cum of soil.
16.3.4.8 Measurements : The filling shall be measured and quantity of earth work computed from cross
sections of filling or the embankment. No deduction shall be made for voids.
16.3.4.9 Rate shall include the cost of all operations described above including operation mentioned in 16.3 to
the extent applicable.
16.4 SUPPLYING AND STACKING OF MATERIALS

16.4.1 Aggregates/Red Bajri
16.4.1.0 The item of work shall specify stone aggregate/brick aggregate/red bajri etc., as the case may be.
16.4.1.1 Stacking : Ground where stacks are proposed to be made shall be cleared, levelled or dressed to a
uniform slope and all lumps, depressions etc. shall be removed. The stacked metal shall be free from vegetation
and other foreign matter. Coarse aggregates stack shall be made at places as directed by the Engineer-in-
Charge. All rejected stone metal shall be removed from the site.
The aggregate shall be stacked in convenient units of one metre top width, 2.2 m bottom width, 60 cm
height and of length in multiples of 3 m for new roads. Where berm width is limited or for repair works it shall
be stacked in units of 40 cm top width 1.4 m bottom width, 50 cm height and length in multiples of 3 m.
Template of steel shall be used for making the stacks and shall always be kept at site for check measurements.
The Engineer-in-Charge may permit stacking in different sizes and height ranging between 45 to 75 cm for
new roads and 40 to 60 cm for repair work, in case the site conditions so demand. In a particular reach of road
as decided by the Engineer-in-Charge, the quantity of stacked material shall be comparable to the theoretical
quantity required for W.B.M. to be laid in that reach.

The stacks shall be uniformly distributed along the road and shall be numbered serially. The number plate shall
be planted on each stack, which shall remain in position until the stack is used in the work. A register showing daily
consumption of stacks shall be maintained at site of work. The collection of stone metal shall be for completed
length of one km (for each layer of W.B. macadam) or as directed by the Engineer-in-Charge in writing.
16.4.1.2 Measurements : Length, breadth and height shall be measured correct to a cm. The total quantity
so arrived shall be reduced by 7.5% to arrive at the net quantity for payment, in cases of aggregates. No such
reduction shall be made in case of fine aggregate i.e. Red Bajri & screening etc. as defined under clause
16.1.1 to 16.1.2.
16.4.2 Binder
16.4.2.1 Stacking : Specified binder shall be brought to the site of work in the sealed original containers.
Binder brought in damaged containers shall not be allowed. The material shall be stacked in fenced enclosures,
as directed by the Engineer-in-Charge, on one side of the roadway. The material shall be purchased from
reputed firms or their authorised dealer. All the drums brought to site shall be serially numbered and used in
the same order. The materials shall be brought in at a time in adequate quantities to suffice for the whole work
or for atleast a fortnight’s work.
For major bituminous road works, supply of bitumen in bulk may be taken for economical reasons, or if
the contingencies of the work so require. Sufficient storage arrangement shall be made at site for atleast ten
days requirement.
Materials shall be kept in the joint custody of the contractor and the representative of the Engineer-in-
Charge. The empty containers shall not be removed from the site of work, till the relevant item of work has been
completed and permission obtained from the Engineer-in-Charge. A few drums may be removed before completion
of work for heating bitumen and mixing aggregates etc. with the permission to the Engineer-in-Charge.
Empty drums required to be returned to stores shall be in good condition. Recovery rate for non-return of
the empty drums or for the damaged drums shall be as decided by the Engineer-in-Charge.
16.4.2.2 Measurements : The materials shall be recorded as per standard weights of different type of container
as intimated by manufacturers. The material shall be weighed where containers are found leaking.
16.4.2.3 Rate : The rate shall include the cost of all labour and materials involved in all the operations
described above.
16.4.3 Moorum/Stone Chippings/Good Earth

16.4.3.0 The item of work shall specify moorum/stone chippings/Good Earth as the cases may be.
16.4.3.1 Stacking : Ground where stacks are proposed to be made, shall be dressed to a uniform slope and
all lumps, depressions etc. shall be removed. Sample of moorum shall be got approved from the Engineer-in-
Charge, before the material in bulk is brought to site.
Moorum/Good Earth shall be stacked in convenient units of one cubic metre in between aggregate stacks
in each length of 100 m as per requirement. The stacks shall be made with wooden boxes open at both ends
and of 2 × 2 × 0.25 m dimensions. These shall always be kept at site for stacking and check measurement.
The stacks shall be uniformly distributed along the road. The supply of moorum shall be completed for the
entire work or for a complete length of one km or as directed by the Engineer-in-Charge in writing.
16.4.3.2 Measurements : Lengh and breadth of boxes shall be measured correct to a cm. Volume shall be
calculated in cubic metres, correct to two places of decimal.
16.4.3.3 Rate : The rate shall include the cost of all materials and labour involved in all the operations
described above.

16.5 EARTHWORK IN ROAD CONSTRUCTION
16.5.1 Earthwork connected with road construction fall broadly into three categories.
(a) Earthwork in cutting including borrow pits.
(b) Earthwork in fillings in embankments (without optimum moisture conditions).
(c) Earthwork in fillings in embankments (under optimum moisture conditions).
16.5.2 Detailed specifications relating to Earthwork already described in subhead Earth Work, CPWD
Specification Vol- I, 2019 so far as the various options in the earthwork for road construction as indicated
below shall be applicable.
• Site clearance
• Setting out and making profile
• Blasting operations
• Excavation in all kinds of soils
• Excavation in ordinary/hard rock
• Earthwork in filling
• Measurements
• Rates
• Surface excavation
• Rough excavation and filling
16.5.3 In addition to the above, there are certain special requirements of earthwork for road constructions,
especially in embankments and excavations from borrow pits. These shall broadly conform to.
(a) IRC : 36 Recommended practice for construction of earth embankments for road works.
(b) IRC : 10 Recommended practice for borrow pits for road embankments by manual operations.
Excavation from borrow pits shall conform to provisions in para 3 of IRC: 10 and the road embankment
shall generally conform to section, slopes and location of borrow pits as per Fig. given in CPWD Specifications
Vol. I, 2019.
16.6 EMBANKMENT CONSTRUCTION (WITHOUT OPTIMUM MOISTURE CONDITIONS)

16.6.0 In addition to what is described in 16.5 above, the following shall apply : materials used in embankments
shall be earth moorum, gravel, a mixture of these or any other material approved by the Engineer-in-Charge.
Such materials shall be free of logs, stumps, roots, rubbish or any other ingredient likely to deteriorate or
affect the stability of the embankment. The work shall be so planned and executed that the best available
materials are saved for the top portion of the embankment.
Highly expansive clays exhibiting marked swell and shrinkage properties may be deposited only at the
bottom of the embankment and no such material shall be placed nor permitted to remain in the top 500 mm
portion of the embankment below the sub-grade.
16.6.1 Preparation of Foundations

The foundations of the embankment shall be ploughed to a depth of 15 to 25 cm. All clods shall be broken into
fine earth and the area roughly levelled. The surface shall then be well watered before the earth work is started.
16.6.2 Source of Supply

16.6.2.1 The material used in embankment shall be obtained either from cutting high ground or from borrow
pits as directed by the Engineer- in-Charge. In case of road embankments, the borrow pits may be excavated

along the sides of the road so as to form road side drains with proper slopes and sections. The clear berm
width between the toe of the bank and the inner edge of the borrow pits shall be specified by the Engineer-in-
Charge but it shall not be less than 5 metres after making due allowance for future development.
16.6.2.2 Borrow pits shall be rectangular in shape with one side parallel to the centre line of the road. If on road
land, these shall be dug as near the boundary as possible. Borrow pits shall not be dug continuously. Ridges
of not less than 8 metres width should be left at intervals not exceeding 300 metres. Small drains should be
cut through the ridges to facilitate drainage. Borrow pits shall be well drained. The bed level of the borrow pits,
shall, as far as possible, slope down progressively towards the nearest cross drain, if any and shall not be
lower than the bed of the cross drain. Borrow pits shall not be dug within 0.8 km of towns or villages. If
unavoidable these shall not exceed 30 cm in depth and shall be drained.
16.6.2.3 Where it becomes necessary to borow filling materials from temporarily acquired cultivable lands the
depth of borrow pits shall not exceed 45 cm. The top soil to a depth of 15 cm shall be stripped and stacked
aside. Thereafter soil shall be dug out to a further depth not exceeding 30 cm and used in forming the
embankment. The top soil shall then be spread back on the land.
16.6.2.4 In case of flood and marginal banks, earth shall be obtained from borrow pits on the river side of the
banks. No borrow pit shall be excavated on the land side of the bank, unless permitted by the Engineer -in-
Charge in writing depending upon the depth of borrow pits and height of embankment. However the minimum
berm width between the toe of the bank and the edge of the borrow pits on the river side shall be 15 metres and
that between the toe of the bank and the edge of the borrow pits on the land side 25 metres.
16.6.2.5 Guide-banks shall be constructed from material obtained from excavation for laying stone aprons
and further borrow pits excavated if necessary, according to the directions of the Engineer-in-Charge.
16.6.3 Earth Filling and Compactions

16.6.3.1 Before commencement of filling the toe lines of the embankment shall be marked by pegs driven into
the ground at 15 metres intervals and by continuous nicking (daf balings) to indicate the limits of the side
slopes. Bamboo and string profiles shall be erected at every 60 metres interval in straight reaches and 15
metres apart in curved portions.
16.6.3.2 Embankment material shall be laid in 20 cm layers which shall be continuous and parallel to the
finished grade. The placing of earth fill shall be done in the full width of embankment including slopes, and the
section of formation shall be kept slightly sloping away from the centre to avoid pools of water forming due to
rain. The height of filling in different sections shall be uniform as far as possible. All clods shall be broken while
the earth is being placed. Organic matter of any kind shall be removed and disposed off as directed by the
Engineer-in-Charge.
16.6.3.3 Joining of old and new embankments shall be done by stepping in an overall slope of about 1 to 5.
16.6.3.4 Each layer of earth shall be adequately watered to aid compaction.
16. 6.3.5 If the material delivered to the road bed is too wet it shall be dried by aeration and exposure to the
sun, till the moisture content is acceptable for compaction. It shall then be rolled with roller of minimum 1/2
tonne weight, not less than 5 times, till it gets evenly and densely consolidated with wooden or steel rammers
of 7 to 10 kg weight having a base of 20 cm square or 20 cm diameter. The labour for ramming shall be atleast
one rammer to six diggers. Every third layer of earth and the top most layer shall be well consolidated with a
power roller of minimum 8 tonnes weight, rolled not less than 5 times, till the soil behaves as an elastic
material and gets compressed only elastically under the load of roller.
16.6.3.6 Dressing : The embankment shall be dressed neatly to the required level as per designed section
and grade, after it has been completed and thoroughly consolidated. The top and slopes shall be protected
from any damage and maintained, till the work is completed and handed over to the Engineer-in-Charge.

16.6.4 Embankment Around Structures
16.6.4.1 To avoid interference with the construction of abutments, wing walls or return walls of culvert/bridge
structure, the contractor shall at points to be determined by the Engineer-in -Charge suspend work on embankments
forming approaches to such structures, until such time as the construction of the latter of sufficiently advanced
to permit the completion of approaches without the risk of interference of damage to the bridge works.
16.6.4.2 Unless directed otherwise, the filling around culverts, bridges and other structures upto a distance of
twice the height of the embankment shall not be done. The fill material shall not be placed against any
abutment or wing wall unless permission has been given by the Engineer-in-Charge but in any case not until
the concrete or masonry has been in position for 14 days. The embankment shall be brought up simultaneously
in equal layers on each side of the structure to avoid displacement and unequal pressure. The sequence of
work in this regard shall be got approved from the Engineer-in-Charge.
16.6.4.3. Where the provision of any filter medium is specified behind the abutment, the same shall be laid in
layers simultaneously with the laying of fill material. The material used for filter material shall conform to the
requirements for filter medium as specified. Payment for providing filter material shall be made separately
under relevant items.
16. 6.4.4. Where it may be impracticable to use power roller or other heavy equipment, compaction shall be
carried out by mechanical tempers or other methods approved by the Engineer-in-Charge. Care shall be taken
to see that the compaction equipments does not hit or come too close to any structural member so as to
cause any damage to it.
16.6.5 Earth Work for Widening Existing Road Embankment

16.6.5.1 When an existing embankment is to be widened and its slope is steeper than 4:1 continuous horizontal
benches each at least 0.3 metre wide, shall be cut into the old slope for ensuring adequate bond with the fresh
embankment material to be added. The material obtained from cutting of benches could be utilised in the
widening of the embankment. However, when the existing slope against which the fresh material is to be placed
is flatter than 4:1 the slope surface may only be ploughed or scarified instead of resorting to benching.
16.6.5.2 Where the width of the widened portion is insufficient to permit the use of standard rollers compaction
shall be carried out with the help of sheep’s foot roller mechanical tampers or other approved equipment. End
dumping of material from trucks for widening operations shall be avoided except in difficult circumstances
when the extra width is too narrow to permit the movement of any other type of hauling equipment.
16.6.6 Cutting
Where the formation level of the road is lower than the ground level, cutting shall be done up to formation
level. Side slopes except in rock cutting shall be evenly and truly dressed.
16.6.6.1 Disposal of Surplus Earth : Earth from cutting shall be utilized for filling in embankment as directed
by the Engineer-in- Charge. Earth not required for embankment shall be disposed off as directed by the
Engineer -in-Charge. The area where the surplus earth is disposed off shall be levelled and neatly dressed.
When the surplus earth is disposed off at a distance of more than 50 metres the extra lead shall be paid for.
16.6.6.2 Measurements : The quantity of earth work shall be calculated by measuring the volume of earth excavated
from the borrow pits and shall be done as specified where it is not possible or convenient to take measurements
from cutting the filling shall be measured and the quantity of earth work computed from cross sections of the filling.
The quantity of earth work so computed shall be reduced by 5% to arrive at the quantity for payment.
For the purpose of taking measurements of earth work in cutting or embankment, ground levels of the area
shall be recorded as specified in 16.5.
16. 6.6.3 Rate : It includes the cost of all the operations described above. The lead and lift for depositing the
earth or disposal of unsuitable material shall be as described in the description of item. It also includes the
Sub Head 2.0 Earth Work.

16.7 WATER BOUND MACADAM WITH STONE AGGREGATE
16.7.1 Water Bound Macadam with Stone Aggregate
Stone aggregate of specified size is used. This is a standard sub base/base and is used where stone
aggregate is available at reasonable rates. This consists of clean crushed coarse aggregate mechanically
interlocked by rolling and voids thereof filled with screening and binding material with the assistance of water,
laid on a prepared sub grade, sub-base, base or existing pavement as the case may be. Water bound
macadam may be used as a sub base, base course or surfacing course.
16.7.2 Approximate Quantities of Materials

Quantities of coarse aggregate, screening and binding material required to be stacked for 100 mm
approximate compacted thickness of W.B.M. for 10 sqm shall be as per table 16.12 for stone aggregate of the
size 90 mm to 45 mm. For stone aggregate of other size, 63 mm to 45 mm and 53 mm to 22.4 mm quantity
of coarse aggregate and stone screening for 75 mm approximate compacted thickness of WBM base for 10
sqm. shall be as per Table 16.13.
TABLE 16.12
Coarse Aggregate Stone Screenings Binding
Material
Classification Size Range Loose Grading/classification Loose Quantity
Quantities and size Quantity
Grading 1 90 mm to 1.21 cum to Type A 0.27 cum to 0.08 cum to
45 mm 1.28 cum 13.2 mm 0.30 cum 0.10 cum
Note : Net quantity = Loose quantity measured in stacks minus 7.5%.
TABLE 16.13
Coarse Aggregate Stone Screenings
Classification Size Compacted Loose Grading For WBM Sub- For WBM surface
Range Thickness Quantity Classification & base/Base Course course (Loose
Size (Loose Quantity) Quantity)
Grading 2 63-45 mm 75 mm 0.91 to Type A 0.12 cum to 0.15 cum 0.10 cum to
0.96 m3 13.2 mm 0.12 cum
-Do- -do- -do- -do- Type B 0.20 cum to 0.22 cum 0.16 cum to
11.2 mm 0.18 cum
Grading 3 53-22.4 75 mm -do- Type B 0.18 cum to 0.21 cum 0.14 cum to
mm 11.2 mm 0.17 cum
* Note : 1. The quantity of metal measured in stacks and reduced by 7.5% to calculate net quantity.
2. The above mentioned quantities should be taken as a guide only for estimation of quantities
for construction etc.
16.7.3 The quantity of binding material required for 75 mm (approximate) compacted thickness will be 0.09
cum/10 sqm in the case of W.B.M. base course and 0.13 cum/10 sqm when the W.B.M. is to function as a
surface course.
16.7.4 Preparation of Foundation

In the case of an existing unsurfaced road, where new materials is to be laid, the surface shall be scarified
and reshaped to the required grade, camber and shape as necessary. Weak places shall be strengthened,
corrugations removed and depressions and pot holes made good with suitable materials, before spreading the
aggregate for W.B.M.

Where the existing surface over which the sub base of W.B.M. is to be laid is black topped, to ensure
effective internal drainage, furrows 50 mm x 50 mm (depth of furrows increased to reach bottom of bituminous
layer where necessary) at one metre intervals shall be cut in the existing bituminous surface at 45 degree C
to the central line of the carriageway before the W.B.M. is laid.
16.7.5 Provision of Lateral Confinement of Aggregates

Before starting with W.B.M. construction, necessary arrangements shall be made for lateral confinement
of aggregates. One method is to construct side shoulders in advance to a compacted layer of the W.B.M.
coarse (Fig.16.1). Inside edges may be trimmed vertical and the included area cleaned off all spilled materials
thereby setting the stage for spreading the coarse aggregate.
The practice of laying W.B.M. after excavating a trench section in the finished formation must be completely
avoided.
16.7.6 Spreading Aggregate

The coarse aggregate shall be spread uniformly and evenly upon the prepared base in required quantities
with a twisting motion to avoid segregation. In no case shall these be dumped in heaps directly on the area
where these are to be laid nor shall their hauling over a partly completed base be permitted. The aggregates
shall be spread uniformly to proper profile by using templates placed across the road six metres apart. Where
specified, approved mechanical devices may be used to spread the aggregates uniformly. The levels along the
longitudinal direction upto which the metal shall be laid, shall be first obtained at site to the satisfaction of
Engineer-in-Charge, and these shall be adhered to.
The surface of the aggregate spread shall be carefully trued up and all high or low spots remedied by
removing or adding aggregate as may be required.
The W.B.M. sub-base shall be normally constructed in layer of 100 mm compacted thickness and W.B.M.
base shall be normally constructed in layers of 75 mm compacted thickness. No segregation of large or fine
particles shall be allowed and the coarse aggregate as spread shall be of uniform gradation with no pockets
of fine material.
The coarse aggregate shall normally not be spread in lengths exceeding three days average work ahead
of the rolling and blending of the proceeding section.
16.7.7 Rolling
Immediately following at spreading of the coarse aggregate, it shall be compacted to the full width by
rolling with either the three- wheel- power -roller of 8 to 10 tonnes capacity or an equivalent vibratory roller.
Initially, light rolling is to be done, which shall be discontinued when the aggregate is partially compacted with
sufficient void space in them to permit application of screenings.
The rolling shall begin from the edges with the roller running forward and backward and adding the screenings
simultaneously until the edges have been firmly compacted. The roller shall then progress gradually from the
edges to the centre, parallel to the centre line of the road and overlapping uniformly each preceding rear wheel
track by one half width and shall continue until the entire area of the course has been rolled by the rear wheel.
Rolling shall continue until the road metal is thoroughly keyed with no creeping of metal ahead of the roller.
Only slight sprinkling of water may be done during rolling, if required. On superelevated curves, the rolling shall
proceed from the lower edge and progress gradually continuing towards the upper edge of the pavement.
Rolling of sub base shall not be done when the sub-grade is soft or yielding or when the rolling causes a
wave like motion in the sub-base or sub-grade. When rolling develops irregularities that exceed 12 mm when
tested with a three metre straight edge, the irregular surface shall be loosened and then aggregate added to
or removed from it as required and the area rolled until it gives a uniform surface conforming to the desired
cross-section and grade. The surface shall also be checked transversely by template for camber and any
irregularities corrected in the manner described above. In no case shall the use of screenings to make up
depressions be permitted.

16.7.8 Application of Screenings
After the coarse aggregate has been lightly rolled to the required true surface, screenings shall be applied
gradually over the surface to completely fill the interstices. Dry rolling shall be continued while the screenings
are being spread so that the jarring effect of the roller causes them to settle into the voids of the coarse
aggregates. The screenings shall not be dumped in piles on the coarse aggregate but shall be spread uniformly
in successive thin layers either by the spreading motion of the hand, shovels or a mechanical spreader.
The screenings shall be applied at a slow rate (in three or more applications) so as to ensure filling of all
voids. Rolling and brooming shall continue with the spreading of the screenings. Either mechanical brooms or
hand brooms or both may be used. In no case shall the screenings be applied, so fast and thick as to form
cakes, ridges on the surface making the filling of voids difficult, or to prevent the direct bearing of the roller on
the coarse aggregates. The spreading, rolling and brooming of screenings shall be performed on sections
which can be completed within one day’s operation and shall continue until no more screenings can be forced
into the voids of the coarse aggregate. Damp and wet screenings shall not be used under any circumstances.
16.7.9 Sprinkling and Grouting

After spreading the screening and rolling the surface shall be copiously sprinkled with water, swept and
rolled. Hand brooms shall be used to sweep the wet screening into the voids and to distribute them evenly.
The sprinkling, sweeping and rolling operations shall be continued and additional screenings applied where
necessary until the coarse aggregates are well bonded and firmly set for the entire depth and until a grout has
been formed of screenings and water that will fill all voids and form a wave of grout ahead of the wheels of the
roller. The quantity of water to be used during the construction shall not be excessive so as to cause damage
to the sub-base or sub-grade.
16.7.10 Application of Binding Material

After the application of screenings and rolling, a suitable binding material shall be applied at a uniform and
slow rate in two or more successive thin layers. After each application of binding material, the surface shall be
copiously sprinkled with water and the resulting slurry swept in with hand brooms or mechanical brooms or
both so as to fill the voids properly. The surface shall then be rolled by a 8-10 tonne roller, water being applied
to the wheels in order to wash down the binding material that may get stuck to the wheels. The spreading of
binding material, sprinkling of water, sweeping with brooms and rolling shall continue until the slurry that is
formed will, after filling the voids form a wave ahead of wheels of the moving roller.
16.7.11 Setting and Drying

After final compaction of the course, the road shall be allowed to cure overnight. Next morning defective
spots shall be filled with screenings or binding material, lightly sprinkled with water, if necessary and rolled.
No traffic shall be allowed till the macadam sets.
16.7.12 Surface Evenness

The surface evenness of completed W.B.M. sub -base in the longitudinal and transverse directions shall
be as specified in Table 16.14 for sub base with stone aggregate of size 90-45 mm and above.
TABLE 16.14
Size of Coarse Longitudinal profile measured with a 3 metre straight edge Cross profile
aggregates Maximum Max. No. of Undulations permitted in Max. permissible
permissible any 300 m length exceeding undulation when
undulation measured with a
camber template
15 mm 10 mm
90-45 mm & 15 mm - 30 12 mm
above
The longitudinal profile shall be checked using a 3 meter long straight edge and graduated wedge at the
middle of each traffic lane along a line parallel to the Centre line of the road. The transverse profile shall be
checked with adjustable template at intervals of 10 meters. For base with stone aggregate of size 63 to 45
mm and 53 to 22.4 mm surface evenness to be as per Table 16.15.

TABLE 16.15
Size of Coarse Longitudinal profile measured with a 3 metre straight edge Cross profile
aggregates Maximum Max. No. of Undulations permitted in Max. permissible
permissible any 300 m length exceeding undulation when
undulation measured with a
camber template
15 mm 10 mm
63-45 mm and 12 mm - 30 8 mm
53-22.4 mm
The longitudinal profile shall be checked with a three metre long straight edge and graduated
wedge at the middle of each traffic lane along a line parallel to the centre line of the road. The
transverse profile shall be checked with adjustable templates at intervals of 10 metres.
16.7.13 Rectification of Defective Construction

Where the surface irregularity of the W.B.M. sub-base course exceeds the tolerances specified
in Table 16.14 or where the course is otherwise defective due to sub grade soil mixing with the
aggregates, the layer to its full thickness shall be scarified over the affected area, reshaped with
added material or removal and replaced with fresh materials as applicable, and recompacted. The
area treated in the aforesaid manner shall not be less than 10 sqm. In no case shall depressions be
filled up with screenings and binding materials.
16.7.14 Meaurements
The length and breadth shall be measured to the nearest centimetre. The depth of consolidated
layer shall be computed to nearest half centimetre by taking average of depths at the centre and at
30 cm from the left and right edges at a cross section taken at 100 metre interval or less as decided
by the Engineer-in-Charge by making small pits. The consolidated cubical contents shall be calculated
in cubic metres correct to two places of decimal. The cubical contents shall be compared with net
quantity of stone aggregates paid (that is stacked quantity – 7.5%). If the cubical contents are within
(±) 5% of the paid net stacked quantity of stone aggregates, the work shall be treated as acceptable.
If the cubical contents is short of net stacked quantity by more than 5% then the payment shall be
restricted to the quantities derived from cubical content.
16.7.15 Rate
above, except cost of stone aggregate, kankar moorum, screenings and bajri, for which separate
payments shall be made. Where W.B.M. is to be laid over an existing road, scarifying and consolidation
of the aggregate received from scarifying shall be paid for separately.
16.8 WATER BOUND MACADAM WITH BRICK AGGREGATE (OVERBURNT (JHAMA) BRICK
AGGREGATE)
16.8.0 Over burnt (jhama) brick aggregate of size 120 mm to 40 mm or 90 mm to 45 mm is used. This
is used when stone aggregate is costly and over burnt brick aggregate is available at reasonable
rates. This is also used over soft clayey sub grade with high moisture contents and low CBR values.
16.8.1 Quantities of Materials

Approximate quantity of brick aggregate (to be paid for separately) required to be stacked for
100 mm average compacted thickness of W.B.M. sub-base shall be 1.60 cum (approximate). The
quantity of binding material, if required shall be as specified by the Engineer-in-Charge. Brick aggregate
shall be broken from overburnt or well burnt brick bats. It shall be homogeneous in texture, roughly
cubical in shape, clean and free from dirt and other foreign matter.

16.8.2 Foundation shall be prepared as specified in 16.7.4.
16.8.3 For spreading aggregate clause 16.7.6 shall apply except that the quantities of materials
shall be as given above.
16.8.4 The rolling shall be done as specified in 16.7.7 except that rolling shall be done with the light
power roller. The use of screenings shall also be omitted. Rolling shall be done 3 to 5 times for each
layer.
16.8.5 For rolling with Binding material clause 16.7.10 shall apply except that rolling shall be done
with a light power roller instead of a heavy road roller and water shall not be used during rolling.
Rolling shall be done 3 to 5 times for each layer.
16.8.6 Surface Evenness rectification of Defective construction, Measurements and Rate shall be as
specified under 16.7.12 to 16.7.15.
16.9 BAJRI PATHS

16. 9.1 Preparation of Sub-Grade
The formation for a width equal to that of the bajri path shall first be cut to a depth, below the
proposed finished level, equal to the thickness of the course of brick aggregate (due allowance
being made for consolidation) and dressed off in level to the finished profile.
In case of made up soil, adequate watering shall be done so that earth settles down as much as
possible and the same rolled up with a minimum three tonnes or light power roller, as directed by the
Engineer-in-Charge.
16.9.2 Laying and Packing Brick Aggregate : Shall be as specified in 16.7.6 except that brick
aggregate shall be used instead of stone aggregate and laid to 7.5 cm depth unless specified
otherwise.
16.9.3 Consolidation : Shall be as specified in 16.7.7 except that rolling shall be done by three
tonnes or light power roller instead of by heavy road roller as directed by the Engineer-in-Charge.
16.9.4 Rolling with Blinding Materials : Shall be as specified in 16.7.10 except that rolling shall be
done by three tonnes or light power roller instead of by heavy road roller as directed by the Engineer-
in-Charge.
16.9.5 Measurements
The finished work shall be measured between the kerb or channel stones or brick edging etc. as
the case may be. Length and breadth shall be measured, correct to a cm. The area shall be calculated
in square metres, correct to two places of decimal.
16.9.6 Rate
The rate shall include the cost of materials and labour involved in all the operations described above.
16.10 BRICK EDGING

16.10.1 Edging
Trenches of specified width and depth shall first, be made along the edges of the wearing course
of the road to receive the bricks. The bed of trenches shall be compacted to a firm and even surface
and then the bricks shall be laid with its length at right angle or parallel to the side of the road
depending upon the width of edging as specified in the item. The bricks shall be abutting against the
wearing course, true to line, gradient and in camber with the finished road surface at the edge.

16.10.2 Finishing
Berms and road edges shall be restored with excavated earth and consolidated by manually. All
surplus earth including rubbish etc. shall be disposed off as directed by the Engineer-in-Charge.
Length of the finished work shall be measured in running metres along the edges of the road
correct to a cm.
16.10.4 Rate
16.11 SCARIFYING METALLED (WATER BOUND) SURFACE

16.11.1 Scarifying
All dirt, dust, cacked up mud, slush, animal droppings, vegetation and all other rubbish shall be
removed from the water bound macadam surface.
The macadam surface shall be scarified to a depth of approximately 5 cm with such additional
picking of high parts of the road as may be necessary to the required camber and gradient as
directed by the Engineer- in-Charge. Any hollows that remain after picking shall be filled with new
aggregate 50 mm nominal size and well consolidated to bring the surface to template.
16.11.2 Finishing
The scarified aggregate shall be raked to bring smaller stones on the top and surface brought to
the required camber and gradient with tolerance of 12 mm longitudinally as well as transversely.
All rubbish etc. shall be disposed off as directed by the Engineer-in-Charge. Scarifying operation
will also include consolidation with road roller the aggregate received from scarifying, although this
aggregate will be consolidated along with aggregate of new wearing course to be paid separately.
The finished work shall be measured between the kerb or channel stones or brick edging etc. as
the case may be. Length and breadth shall be measured correct to a cm. The area shall be calculated
in square metres correct to two places of decimal.
16.11.4 Rate
The rate shall include the cost of labour and materials involved in all the operations described
above except the cost of stone aggregate which shall be paid for separately.
16.12 DRY STONE PITCHING

16.12.1 Stones
These shall be clean, hard stones, free from decay and weathering. They shall be in block and
hammer dressed on all sides.
The size of the pitching stones shall be approximately 22.5 cm.in depth and not less than 15 cm.
in any other direction.

The sides and bottom of earth work to be pitched, shall be brought to the required slope and
gradient and shall be compacted to a firm and even surface.

16.12.3 Pitching
Pitching shall be of 22.5 depth unless specified otherwise. Profiles shall be put up by means of
pegs and strings or by placing stones, at intervals of not more than 15 cm. Stones shall then be laid
closely in position in between the profile and firmly embedded with joints staggered and with exposed
faces true to line, gradient and in uniform slope throughout.
Cross bands of approximately 22.5 cm. width through bond stones equal to the full depth of
pitching shall be provided at an interval of approximately 3 metres centre to centre both longitudinally
and transversely.
The interestices between adjacent stones shall be filled in with stones of proper size, well driven
in with crow bars to ensure tight packing and complete filling of all interstices. Such filling shall be
carried on simultaneously with the placing in position of the large stones and shall in no case be
permitted to fall behind. Final wedging shall be done with the largest sized chip practicable, each
chip being well driven home with a hammer so that no chip is possible of being picked up or removed
by hand.
The measurements shall be taken in sqm. The area of pitching for drains shall be calculated by
multiplying the perimeter (bed width plus side slopes) by the length of the pitching. The length, width
and side slope shall be measured correct to a cm.
16.12.5 Rate
The rate shall include the cost of the materials and labour involved in all the operations described
above, except pitching stone, if specified, shall be paid for separately.
16.13 BRICK PITCHING

16.13.1 Bricks shall be all class designation 75 unless otherwise specified. The specification of
bricks shall be as per SH 6.00 (Brick work) CPWD Specification – 2019.

The sides and bottom of earth work to be pitched, shall be brought to the required slope and
gradients and shall be compacted to a firm and even surface.
16.13.3 Pitching
Pitching shall be 10 cm. in depth or in multiples of 10 cm. as specified. Profiles shall first be put up
by means of pegs and strings or by placing bricks at intervals not more than 15 cm. Bricks shall then
be laid in parallel rows breaking bond or Herring –bone bond pattern as directed. In the case of
drains, bricks shall be laid on bed width in parallel rows breaking bond and on sides in either of the
above manner. At the top, the toe and at every 3 m. intervals, brick courses shall be laid with bricks
on ends. All bricks shall be laid closely in position and firmly embedded, true to line, gradient and in
uniform slope through out pitching work.
Para 16.12.4 shall apply, except that the measurements of the dry pitching 10 cm. deep for the
drains shall be taken by adding 10 cm. on either side to the perimeter of the drain so as to allow for
the top 20 cm. courses. In this case the perimeter of the drain (bed width plus sides slopes) plus 20
cm. multiplied with the length of the pitching shall give the area of the pitching in sqm.
16.13.5 Rate
The rate shall include the cost of material and labour involved in all the operations described
above.

16.14 CUTTING W.B.M. ROADS AND MAKING GOOD
16.14.1 Cutting
All road crossings shall be cut in half the width at a time and repaired, unless otherwise permitted
by the Engineer-in-Charge. Cutting shall be straight and uniform in width. Soling stone and aggregate
obtained from cutting macadam shall be stacked separately, clear of the road surface. Aggregate
shall be screened. Stones of size below 20 mm and with rounded edges shall be discarded and
disposed.
16.14.1.2 Making Good

16.14.1.2.1 After the trenches have been filled in with excavated earth in layers of 15 cm thickness,
watered, well consolidated with heavy iron rammers and brought to sub grade level, soling stone
obtained from cutting shall be laid as per existing soling and consolidated with heavy iron rammers.
Where the earth consolidation is well done, no settlement need occur subsequently, for this excess
watering should be avoided.
16.14.1.2.2 New aggregate 50 mm nominal size or as required, shall be added to old aggregate and
spread over to a depth of 7.5 cm as specified in 16.7.6. This shall then be consolidated with hand
roller or heavy iron rammers, as directed, first with light sprinkling then with sufficient application of
water till the aggregate has become adequately consolidated and does not get displaced. All
undulations shall be loosened by hand picking, surplus aggregate removed from high spots and
depressions filled with surplus and new aggregate and the surface compacted again. When thoroughly
consolidated, kankar moorum and red bajri, freshly collected shall be spread over it in 12 mm layer
and consolidated with hand roller or heavy iron rammers, with sufficient application of sufficient water
till a uniform surface is obtained.
16.14.2.3 The finished surface shall be in camber and left a little higher than the adjoining road
surface to allow for any settlement on drying.
16.14.1.3 Measurement : Length and width of cutting shall be measured correct to a cm. The area
shall be calculated in square metre, correct to two places of decimal.
16.14.1.4 Rate : The rate shall include the cost of materials and labour involved in all the operations
described above.
16.14.2 Cutting Bituminous Roads and Making Good

16.14.2.1 Cutting, making good and measurements shall be as specified in 16.14.1 except the top
bitu-minous surface shall be finished as per the existing surface or as directed by the Engineer-in-
Charge. The item shall include cutting and restoration of W.B.M. portion as well as Bitumen portion.
16.14.2.2 Rate : The rate shall include the cost of materials and labour involved in all the operations
described above.
16.15 CUTTING BAJRI PATHS AND MAKING GOOD

16.15.1 Cutting
Cutting shall be straight and uniform in width. Brick aggregate obtained from cutting shall be
screened, aggregates of smaller size discarded and disposed off and rest stacked clear off pathway.
16.15.2 Making Good

After the trench has been filled in with excavated earth, consolidated and brought to sub-grade
level, brick aggregates obtained from cutting and mixed with new aggregates 50 mm nominal size, as
required shall be spread to a depth of 7.5 cm as specified in 16.9.2. This shall then be consolidated
with blinding materials and finished as specified in 16.14.1.2

Length and width of cutting shall be measured correct to a cm. The area shall be calculated in
square metre correct to two places of decimal.
16.15.4 Rate
above.
16.16 FENCING WITH G.I. BARBED WIRE AND RCC POSTS (FIG. 16.9)
16.16.1 Materials
R.C.C. posts and struts shall be as specified in 16.1.12. G.I. Barbed wire shall be as per IS 278.
16.16.2 Spacing of Posts and Struts

The spacing between posts shall be three metres centre to centre, unless otherwise specified, or
as directed by the Engineer -in-Charge to suit the dimensions of the area to be fenced. Every 15th,
last but one end post and corner posts shall be strutted on both sides and end posts on one side
only.
16.16.3 Fixing of Posts and Struts

Pits 45 x 45 cm and 75 cm deep or as directed shall first be excavated true to line and level to
receive the posts. In the case of struts, pits 70 x 45 x 75 cm deep or as directed shall be excavated
to suit the inclination of the strut so that it is surrounded by concrete by not less than 15 cm at any
point. The pits shall be filled with a layer of 15 cm thick cement concrete 1:3:6 (1 cement: 3 fine sand:
6 graded stone aggregate 40 nominal size) . The posts and struts shall then be placed in the pits, the
posts projecting 1.2 m or to the specified height above ground, true to line and position. The cement
concrete 1:3:6 shall be filled in upto 15 cm for posts and 25 cm for struts below ground level at the
base of the concrete so that the posts are embedded in the cement concrete block of size 45 x 45 x
60 cm and strut in block of size 70 x 45 x 50 cm. The concrete in foundations shall be watered for at
least 7 days to ensure proper curing. The remaining portions of pits shall be filled up with excavated
earth and the surplus earth disposed off as directed by the Engineer-in-Charge and site cleared.
16.16.4 Fixing G.I. Barbed Wire

The barbed wire shall be stretched and fixed in specified number of rows and two diagonals. The
bottom row shall be 14 cm above ground and the rest at 12.5 cm centre to centre. The diagonals shall
be stretched between adjacent posts from top wire of one post to the bottom wire of the second post.
The diagonal wires will be interwoven with horizontal wires by fixing the odd- rows of wires first , then the
diagonal cross wires and lastly the even rows of wires. The barbed wire shall be held to the R.C.C.
posts by means of G.I. staples fixed to wooden plugs or G.I. binding wire tied to 6 mm barnibs fixed while
casting the posts. Turn buckles and straining bolts shall be used at the end posts, if so specified.
Total length of G.I. barbed wire shall be measured in running meter correct to a cm.
16.16.6 Rate
above but excluding the cost of posts, struts, turn buckle, straining bolts and excavation and concrete
in foundations for which separate payments shall be made under respective items.
16.17 G.I. BARBED WIRE FENCING WITH ANGLE IRON POSTS

16.17.1 Materials
G.I. Barbed wire shall be as per IS 278 and angle iron shall be as per subhead – 10.00 steel work
of CPWD Specification Vol. I- 2019. The angle shall be of size 40 × 40 × 6 mm.

16.17.2 Spacing of Posts and Struts
The spacing of posts shall be 3.00 m centre to centre, unless otherwise specified or as directed
by the Engineer-in-Charge to suit the dimensions of the area to be fenced. Every 15th, last but one
end posts and corner post shall be strutted on both sides and end post on one side only.
16.17.3 Fixing of Posts and Struts

This shall be as per 16.16.3. In addition, angle iron post at bottom shall be split and banded at
right angle in opposite direction for 10 cm length to get proper grip.
16.17.4 Fixing G.I. Barbed Wire

The barbed wire shall be stretched and fixed in specified number of rows and two diagonals. The
bottom row should be 14 cm above ground and the rest at spacing of 2.5 cm centre to centre. The
diagonal shall be stretched between adjacent posts from the top wire of one post to the bottom wire
of 2nd post. The diagonal wire will be inter woven with horizontal wires by fixing the odd rows of wires
first, then the diagonal cross wires and lastly even rows of wires. The barbed wire shall be held by
tearing the holes of 10 mm dia in the post and tied with G.I. wire, turn buckles and straining bolts shall
be used at the end post, if so specified.
This shall be as per 16.16.5.
16.17.6 Rates
above but excluding the cost of post struts turn buckle straining bolts and excavation and concrete in
foundation for which separate payments shall be made under respective item. Angle iron post shall
be paid as per similar item of subhead Steel work of CPWD Specification 2019 Vol-I. No extra payment
shall be made for making holes in angle and nothing shall be deducted on account of holes.
16.18 WELDED STEEL WIRE FABRIC FENCING WITH RCC POSTS

16.18.1 Materials
RCC posts and struts shall be as specified in 16.1.12. Welded steel wire fabric will conform to IS
4948 and shall be of rectangular mesh 75 × 25 mm size weighing not less than 7.75 kg/sqm.
16.18.2 Fixing of RCC posts and struts shall be as described in 16.16.3.
16.18.3 Steel wire fabric 90 cm wide will be fixed to the posts by means of G.I. staple on wooden plugs
or tied to 6 mm bar ribs with binding wire. The steel fabric shall be fixed to leave 15 cm clearance at
the bottom and top of the posts.
16.18.4 Finishing
The steel wire fabric shall be painted with two or more coats of approved shade of enamel paint
over a coat of steel primer as for new work.
16.18.5 R.C.C. Posts, Rails and Pales (Fig. 16.10)

16.18.5.1 Materials : R.C.C. posts, rails and pales shall be as described in 16.1.11 & 16.1.12.
16.18.5.2 Spacing of Posts : The spacing of post shall be as specified, or as directed by the Engineer-
in-Charge to suit the dimensions of the area to be fenced.
16.18.5.3 Fixing Posts : Pits 45 x 45 cm and 70 cm deep or as directed shall first be excavated true
to line and level to receive the posts.

16.18.5.4 Fixing Rails and Pales : The rails shall be slotted into the slots left in the posts, while the
pales shall be simply dovetailed into the rails. The pales shall be fixed by pouring a little grout of 1.2
mix (1 cement : 2 fine sand) into the dovetails. The fencing shall be so erected that on completion is
truly in line and level and top of the fence shall then follow approximately the profile of the ground.
Fencing to be measured in square metre correct to two places of decimal after taking length and
width of the finished work in metre.
16.18.7 Rates
As per item No. 16.16.6.
16.19 ENGRAVING LETTERS IN HARD STONES (FIG. 16.5 & 16.6)

16.19.1 Size of Letters
The letters shall be 13 cm, 10 cm or 8 cm high as per figure respectively.
16.19.2 Engraving
Engraving of the letters to the specified height and thickness shall be done by cutting with snap
incision in V shape, about 12 mm deep or as directed by the Engineer-in-Charge.
16.19.3 Finishing
The engraved portion of the letters shall be painted with black enamel or as directed by the
Engineer-in-Charge.
The height of each letter shall be measured correct to a cm.
16.19.5 Rate
above except the cost of stones and paint for lettering unless specified otherwise.
16.20 BOUNDARY STONES (HARD STONE) (FIG. 16.4)

16. 20.1 Boundary stones shall be as described in 16.1.21 or of size otherwise specified or directed
16.20.2 Spacing and Fixing

The boundary stones shall be fixed as directed by Engineer-in -Charge at intervals of 200 m or
less, where the boundary is in a curve or the land is costly and is likely to be encroached upon, and
(ii) at all angular points of the road boundary.
The boundary stones shall be firmly fixed in ground to a depth of 60 cm and the side filling shall
be thoroughly watered and consolidated.
The lower 60 cm portion of the boundary stones shall be encased on all sides by at least 15 cm
of foundation concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40 mm nominal
size) in case (a) where wet cultivation abuts the road land and boundary stones are likely to be
displaced during agricultural operations (b) where the road runs in built up area, and (c) where the
boundary stones are intended to serve as permanent land marks.
16.20.3 Measurements & Rate

Boundary stone shall be enumerated. The rate shall include the cost of materials and labour
involved in all the operations described above.

16.21 PRECAST RCC BOUNDARY STONE (FIG. 16.4)
16.21.1 RCC Boundary stones shall be manufactured as per standard design or as specified in item and
directed by Engineer-in-Charge.
These shall be of reinforced cement concrete 1:1 ½ : 3 (1 cement : 1 ½ coarse sand : 3 graded stone
aggregate 20 mm nominal size), 90 cm high and 15 cm dia at the top and 20 cm. dia at bottom with necessary
steel reinforcement as per standard design or as directed by the Engineer-in-Charge. The precast RCC
Stones shall be finished smooth with cement mortar 1:3 (1 cement : 3 fine sand).
16.21.2 Spacing, fixing, measurements and rate shall be as described in 16.20.
16.22 KILOMETERS STONES (FIG. 16.7)

16.22.0 Kilometer stone of precast RCC of grade 1: 1 ½ : 3 (1 cement : 1 ½ :3 coarse aggregate 20 mm
nominal size ) of specified size to be used.
16.22.1 Fixing
Trenches 50 cm wide and 45 cm deep shall first be excavated to receive the kilometer stone, the lower 45
portion of kilometer stone shall then be firmly fixed in position in ground and the sides filled with earth,
thoroughly watered and consolidated.
Where so specified the kilometer stone shall be fixed in cement concrete 1:3:6 (1 cement : 3 fine sand :
6 graded stone aggregate 40 mm nominal size) so that there is 15 cm thick concrete in the bottom and 15 cm
thick all round upto formation level. Trench excavation in this case will be made according to the requirements.
16.22.2 Finishing
Precast RCC stone to be finished smooth in cement Mortar 1:3 (1 cement 3 fine sand). The exposed
surfaces above ground shall be painted with two or more coats of required colour or as specified over a coat of
primer as for new work, the background colour shall be white with black letters and numerals for names of
stations and distances. The semi circular portions of kilometer stones on National Highways, State Highways
and Major District Roads shall be painted canary yellow (I.S. shade 221) and white respectively. The route
numbers to be written shall be in black on the canary yellow and white back grounds and in white on the
brilliant green back grounds.
The place names shall be inscribed in different scripts in the order described in Table 16.16. Only one
script shall be used on any one kilometer stone.
TABLE 16.16
Km. No. Script

0 Roman
1 Hindi (Devanagari Script)
2 Local Language
3 Hindi (Devanagari script)
4 Local Language
5 Roman
and so on repeated in the same order
(a) On kilometer stones fixed in other district roads and Village road the inscription may be in the
National language i.e. Hindi in Devnagari script or the script of the recognised regional language of
the place, at the discretion of the Local Road Authority.

(b) Inscription in the Roman script is not necessary unless such a road leads to a place of tourist
or archaeological interest.
(c) The shape and spacing of letters in the Roman script other than Roman, the style of lettering
shall be one in general use. The spacing between single or compound of lettering shall be the one
in general use. The spacing between single or compound letter shall be atleast equal to the
thickness of the vertical strokes or the thickness of strokes of letters in the scripts having no
vertical strokes as in Oriya, Telegu and Kannada.
(d) On the kilometre stones which are inscribed in script other than Roman, the style of lettering
shall be one in general use. The spacing between single or computed of lettering shall be the one
in general use. The spacing between single of letters in the scripts having no vertical strokes as
in Oriya, Telegu and Kannada.
Kilometer stones shall be enumerated.
16.22.4 Rate
The rate shall include the cost of materials and labour involved in all the operations described above, but
excluding the costs of excavation, concrete in foundations painting and lettering for which payment shall be
made separately.
16.23 SURFACE DRESSING ON NEW SURFACE WITH HOT BITUMEN OF GRADE VG- 10 ONE COAT
16.23.0 This type of treatment shall consist of cleaning the existing water bound macadam kankar or gravel
surfaces, and applying one coat of hot bitumen of grade VG- 10 of approved quality using 2.25 kg of bitumen
per sqm with 1.65 cum of stone chippings 13.2 mm nominal size per 100 sqm of road surface on the prepared
base, blinding it with stone chippings of 13.2 mm nominal size and consolidation with a road roller of 6 to 8
tonne capacity. This type of treatment is normally done for a road with light density rubber tyred traffic and
roads for temporary construction. This treatment is also done on existing water bound macadam before
applying the final surface treatment. In the latter case, after applying a coat of painting the road is thrown open
to traffic till the road is consolidated. The final treatment is then given after making good the undulations etc.
in the road surface.
16.23.1 Preparation of surface (Repairs and Cleaning) shall be as specified under 16.24.2(a).
16.23.2 Applying binder, blinding, consolidation, surface finishing, measurements and rates shall be as specified
under 16.24 except that binder shall be applied at the rate of 2.25 kg of bitumen per sqm and stone chippings
of size 13.2 mm at 1.65 cum per 100 sqm unless otherwise specified.
16.24 SURFACE DRESSING ON NEW SURFACE USING HOT BITUMEN OF GRADE VG- 10 —TWO COATS
16.24.0 This consists of the application of two coats of surface dressing each coat consisting of a layer of
bituminous binder sprayed on a base prepared previously, followed by a cover of stone chippings properly
rolled to form a wearing course. The existing water-bound macadam, kankar or gravel surface shall be cleaned
thoroughly before application of bituminous binder. The work shall be carried out only when the atmospheric
temperature in shade is 16 deg C or above. No bituminous material shall normally be applied when the road
surface or material is damp, when the weather is foggy or rainy, or during dust storms.
16.24.1 Materials
Binder i.e. bitumen of grade VG- 10 confirming to IS : 73 shall be as specified and shall conform to Table
16.7 and stone chippings shall conform to grading as the Table 16.17. Unless otherwise specified or directed
by the Engineer -in- Charge the quantities of materials shall be as specified in Table 16.17. A proper record will
be kept to ensure that the daily out-turn of work is co-related with the quantity of bitumen used as per proforma
given in Appendix ‘A’.

TABLE 16.17
Type of Stone Chipping Bitumen Quantity
coat Nominal Specification Quantity VG- 10
Size
First Coat 13.2 mm 100 per cent passing 1.5 cum/100 sqm 1.8 kg per sqm
through IS sieve 22.4 mm of road surface of road surface
square mesh and retained
on IS Sieve 11.2 mm square
mesh
Second 11.2 mm 100 per cent passing 1.0 cum/100 sqm 1.1 kg per sqm
coat through IS sieve 13.2 mm of road surface of road surface
square mesh and retained
on IS sieve 5.6 mm square
mesh
16.24.2 First Coat

(a) Preparation of Surface
Repairs : Pot holes or patches and ruts in the water bound macadam base or surface course
which is to be surface treated, shall be repaired by removal of all loose and defective material by
cutting in rectangular patches and replacement with suitable material.
For the purpose of repairs the area of pot holes shall be taken upto 0.75 sqm and depth upto 5
cm. All pot holes, patches and ruts upto 2.5 cm deep shall be repaired and brought to level with
premix and properly consolidated while those of depths greater than 2.5 cm shall be repaired with
similar specifications as adopted originally.
Cleaning : Prior to the application of the binder, all dust, dirt, caked mud, animal dung, loose and
foreign material etc. shall be removed 30 cm on either side, beyond the full width to be treated, by
means of mechanical sweepers and blowers, if available or otherwise with wire brushes, small picks,
brooms etc. The material so removed shall be disposed off as directed by the Engineer-in-Charge.
For a water bound macadam surface, the interstices between the road metal shall be exposed
upto a depth of about 10 mm by means of wire brushes. The surface shall then be brushed with soft
brooms to remove all loose aggregate. Finally the traces of fine dust which get accumulated while
brushing shall be thoroughly removed from the surface by blowing with gunny bags.
The prepared surface shall be closed to traffic and maintained fully clean till the binder is applied.
(b) Applying Binder (Hot Bitumen) VG- 10 (confirming to IS : 73)

The binder shall be heated in a boiler to a temperature as specified under Table 16.7 for the
grade used and maintained at the temperature, the use of a thermometer being essential.
The binder shall be applied evenly to the clean dry surface by means of a pressure sprayer at
the rate specified. The binder shall be applied longitudinally along the length of the road and never
across it. The edges of the binder surface shall be defined by wire or a rope stretched in position.
Heating in cut out drums and pouring from perforated tins, cans and such other methods shall
not be permitted. Except in the case of petty works and repairs with the specific approval of the
Engineer-in-Charge.
Excessive deposits of binder caused by stopping or starting of the sprayer or through leakage or
any other reason shall be suitably corrected before the stone chippings are spread.

(c) Blinding or Spreading Stone Chippings
Immediately after the binder is applied and while it is still hot, stone chippings free from dust and
in a dry and clean state shall be spread evenly over the surface at the rate specified above. Spreading
shall be done preferably by means of a mechanical gritter, otherwise manually with a twisting motion
to avoid segregation which otherwise shall have to be removed by brushing the excess stone chippings
over the surface into hungry spots to obtain a uniform surface, free from waviness, depressions and
other irregularities. The surface shall be checked by means of a camber board laid across the road
and a three metre straight edge laid parallel to the centre line of the road, and undulations if any
shall be corrected by addition or removal of blindage till a surface free from undulation is obtained.
If a uniform surface is assured at this stage, the completed surface should be normally free from
undulations and unevenness.
(d) Consolidation of Blindage

Immediately following the application of the stone chippings and light brooming, the road surface
shall be compacted by a power roller of 6 to 8 tonnes, starting at edges and working towards the
centre (or to the outside edge in case of superelevated curve). Each pass of the roller shall uniformly
overlap not less than one third of the track made in the preceding pass. The roller shall be worked or
started and stopped without jerks and shall not be stopped or reversed each time at the same
location to cause displacement of stone and other irregularities. Consolidation shall be considered
complete when the stone chippings are firmly embedded.
Generally five to six trips shall be made for thorough compaction of the surface or as may be
specified by the Engineer-in-Charge.
Along kerbs, manholes and all places not accessible to the roller, compaction shall be secured by
means of steel rammers or hand rollers.
16.24.3 Second Coat

(a) Cleaning the Road Surface : The surface shall be examined and any loose material and
foreign matter shall be removed by brooming or blowing off by faning with gunny bags, care
being taken not to loosen the blindage already set.
(b) Applying Binder (Hot Bitumen of Grade VG- 10) : The second coat of binder shall be
applied immediately after the blinding has been set and the surface has been cleaned. The
binder shall be applied at the specified rate in the manner specified for the first coat 16.24.2(b).
(c) Blinding or Spreading Stone Chippings : Immediately after the second application of
binder, the stone chippings shall be spread at the rate specified as above in the manner
described in 16.24.2(c).
(d) Consolidation of Blindage : The specifications described in 16.24.2(d) shall apply. Further
the prepared finished surface shall be protected from traffic for 24 hours or such period as
may be specified by the Engineer-in-Charge.
16.24.4 Surface Finishing

The finished surface shall be uniform and conform to the lines, grades and typical cross-sections
shown in the drawings.
16.24.5 The finished surface shall be thrown open to traffic on the following day. Controlling traffic
shall be done by suitable methods like barricading posting of watchman etc.

The length and width of the finished work shall be measured correct to a cm along the finished surface of
the road. The area shall be calculated in square metre, correct to two places of decimal.
For record purposes, the measurement for binder and stone chippings shall be taken as specified in
16.4.2 and 16.4.3 before they are actually used on the work. Premeasurements of materials taken for record
purposes shall simply serve as a guide and shall not form the basis for payment.
16.24.7 Rate
The rate shall include the cost of materials and labour involved in all the operations described above,
except for repairs described under 16.24.2.
16.25 SURFACE DRESSING ON OLD SURFACE WITH HOT BITUMEN OF GRADE VG- 10 (CONFIRMING
TO IS : 73) ONE COAT
16. 25.0 This treatment consists of cleaning old painted surfaces and applying a coat of hot bitumen of grade
VG- 10 on the prepared base, blinding with stone chippings and consolidation with road roller of 6 to 8 tonne
capacity.
16.25.1 Materials
Binder shall be as specified and conform to Table 16.7 stone chipping shall conform to grading given Table
16.17 for 11.2 mm. Unless otherwise specified or directed by the Engineer-in-Charge stone Chippings of 11.2
mm nominal size shall be used @ 1.50 cum per 100 sqm area and bitumen @ 1.95 kg per square metre area.
A proper record shall be kept to ensure that the daily turn out of work is correlated with the quantity of bitumen
used as per proforma given in Appendix ‘A’.
16.25.2 Preparation of Surface (Repairs and cleaning) shall be as specified under 16.24.2.
16.25.3 Applying binder, Blinding, Consolidation, Surface Finishing, Measurement and Rate shall be as specified
under 16.24 except that the binder and chippings shall be applied at the rate specified above.
16.26 SURFACE DRESSING ON NEW SURFACE WITH BITUMEN EMULSION (MINIMUM 50% BITUMEN
CONTENT RS GRADE CONFIRMING TO IS : 8887) ONE COAT
16.26.0 This treatment consists of cleaning the existing water bound macadam, kankar gravel or stabilized
base and other black top surfaces, applying a coat of bitumen emulsion at atmospheric temperature, blinding
it with stone chippings including consolidation with a road roller.
This type of treatment is normally applied under damp conditions and for minor repair works during rainy
season for roads with medium density, rubber tyred traffic such as service roads. This treatment is also done
on existing water bound macadam before applying the final surface treatment. In the latter case, the road is
consolidated. The final treatment is then given after making good the undulations depressions etc. in the road
surface.
16.26.1 Materials
Binder shall be as specified and shall conform to RS grade confirming to IS : 8887. Stone chipping of 13.2
mm size shall conform to Table 16.17. Unless otherwise specified or directed by the Engineer-in-Charge 13.2
mm stone chippings shall be used @ 1.5 cum per 100 sqm area and bitumen @ 1.95 kg/sqm area. A proper
record shall be kept to ensure that the daily out turn of work is correlated with the quantity of bitumen used as
per proforma given in Appendix ‘A’ .

The specification described in 16.24.2 (a) shall apply except that the binder used for patch repairs etc.
shall be bitumen emulsion.

16.26.3 Applying Binder
The specification described in 16.24.2 (b) shall apply except that bitumen emulsion is not
heated in boilers but it shall be spread at atmospheric temperature at the specified rate. In case
the road surface is very dry the surface shall be very lightly sprinkled with water just before
applying the binder.
16.26.4 Blinding including consolidation, Measurements and Rate shall be as specified under 16.24
except that the stone chippings shall be spread at the specified rate immediately after the bitumen
emulsion on application breaks i.e. changes colour from brown to black.
16.27 SURFACE DRESSING ON OLD SURFACE WITH BITUMEN EMULSION (MINIMUM 50%
BITUMEN CONTENT RS GRADE CONFIRMING TO IS : 8887) ONE COAT
16.27.0 This treatment consists of cleaning old painted surfaces and applying a coat of bitumen
emulsion on the prepared base, blinding with stone chippings and consolidation with a road roller.
This type of treatment is normally done under damp conditions.
16.27.1 Materials
Binder shall be as specified and shall conform to RS grade confirming to IS : 8887. Unless
otherwise specified or directed by the Engineer- in-Charge 11.2 mm the stone chippings shall be
used @ 1.10 cum per 100 sqm area and bitumen @ 1.22 kg per sqm area. A proper record shall be
kept to ensure that the daily out turn of work is correlated with the quantity of bitumen used as per
proforma given in Appendix ‘A’.
16.27.2 Preparation of surface shall be as specified in 16.24.2 (a) except that the binder used for
patch repairs etc. shall be bitumen emulsion.
16.27.3 Applying binder, bitumen emulsion, blinding or Spreading to it including consolidation of

blindage, measurement etc. shall be as specified under 16.24 except for preparation of surface and
that the binder and stone chippings shall be used at the rates prescribed in 16.26.1.
16.28 TACK COAT OF HOT STRAIGHT RUN BITUMEN OF GRADE VG- 10

16.28.0 The rate of application of binder which shall be as specified and which shall conform to
16.1.5 shall depend on the surface on which the premix carpet is to be laid.
(a) 0.75 kg/sqm on W.B.M./ W.M.M. Surface
(b) 0.50 kg/sqm on bitumen surface.
16.28.1 Materials
Bitumen : This shall be straight-run bitumen of grade VG- 10 conforming to IS 73 specifications.
16.28.3 Cleaning
Prior to the application of bitumen, all vegetation, loose sealing compound, caked mud, animal
dung, dust, dirt and foreign material shall be removed from the entire surface of the pavement and
from existing dummy, construction and expansion joints (wherever existing) by means of mechanical
sweepers and blowers, otherwise with steel wire brushes, small picks, brooms or other implements
as approved by the Engineer-in-Charge. The material so removed shall be disposed off as directed
16.28.4 Weather and Seasonal Limitations

The tack coat shall not be applied nor any bitumen work done during rainy weather or when the
surface is damp or wet or when the atmospheric temperature in the shade is not more than 16o C.

16.28.5 Application of Tack Coat
16.28.5.1 Heating : Bitumen shall be heated in a boiler to a temperature of 165 deg. C to 175 deg. C and
maintained at that temperature. Temperature shall be checked at regular intervals with the help of a thermometer.
16.28.5.2 Application of Bitumen : Hot bitumen shall be applied evenly to the clean, dry surface by means
of a pressure sprayer at specified rate. Even and uniform distribution of bitumen shall be ensured. Bitumen
shall be applied longitudinally along the length of the pavement and never across it. Excessive deposits of
bitumen caused by stopping or starting of the sprayer or through leakage or any other reason shall be suitably
rectified.
Length and breadth shall be measured correct to a cm, along the surface of pavement. Area shall be
worked out in sqm correct to two places of decimal.
16.28.7 Rate
Rate shall include the cost of all materials and labour involved in all the operations described above.
16.29 TACK COAT WITH BITUMEN - EMULSION/ HOT BITUMEN OF GRADE VG– 10
16.29.1 Scope
The work shall consist of the application of single coat of low viscosity liquid bituminous material to
existing bituminous, cement concrete or primed granular surface preparatory to the superimposition of a
bituminous mix, as specified in the contractor or as instructed by the Engineer-in-Charge and applied as
specified in the nomenclature of item.
16.29.2 Materials
The binder used for tack coat shall be either cationic bitumen emulsion (RS1) complying with IS:8887 or
suitable low viscosity paving bitumen of VG 10 grade conforming to IS:73. The use of cutback bitumen RC:70
as per IS:217 shall be restricted only for sites at sub-zero temperatures or for emergency applications as
directed by the Engineer-in-Charge. The type and grade of binder for tack coat shall be as specified in the
contract or as directed by the Engineer-in-Charge.
16.29.3 Construction
16.29.3.1 Equipment
The tack shall be applied by a self propelled or towed bitumen pressure sprayer, equipped for spraying the
material uniformly at specified rate. Hand spraying shall not be permitted except in small areas, inaccessible
to the distributor, or narrow strips, shall be sprayed with a pressure hand sprayer, or as directed by the
Engineer-in-Charge.
16.29.3.2 Preparation of Base

The surface on which the tack coat is to be applied shall be clean and free from dust, dirt and any
extraneous material, and be otherwise prepared in accordance with the requirements. The granular or stabilized
surfaces shall be primed as per Para 16.65 clause (priming coat) immediately before the application of the
tack coat, the surface shall be swept clean with a mechanical broom, and high pressure air jet, or by other
means as directed by the Engineer-in-Charge.
16.29.3.3 Application of Tack Coat

The application of tack coat shall be at the rate specified in Table 16.17A and it shall be applied uniformity.
If rate of application of tack coat is not specified in the contract, then it shall be the rate specified in Table
16.17A. No dilution or heating at site RS1 bitumen emulsion shall be permitted. Paving bitumen if use for tack
coat shall be heated to appropriate temperature in bitumen boilers to achieve viscosity less than 2 poise. The
normal range of spraying temperature for a bituminous emulsion shall be 20 C to 70 C and for cutback, 50 C
to 80 C. The method of application of tack coat will depend on the type of equipment to be used, size of
nozzles, pressure at the spray bar and speed or forward movement. The contractor shall demonstrate at a
spraying trial, that the equipment and method to be used is capable of producing a uniform spray, within the
tolerances specified.

Table 16.17A
Rate of application of tack coat
Type of Surface Rate of Spray of Binder in Kg
per sq.m
Bituminous surfaces 0.20-0.30
Granular surfaces treated with primer 0.25-0.30
Cement concrete pavement 0.30-0.35
16.29.3.4 Curing of Tack Coat

The tack coat shall be left to cure until all the volatiles have evaporated before any subsequent
construction is started. No plant or vehicles shall be allowed on the tack coat other than those
essential for the construction.
16.29.4 Measurement of Payment

Tack coat shall be measured in terms of surface area of application in square metres.
16.29.5 Rate
The contract unit rate for tack coat shall be payment in full for carrying out the required operations
including for all components i.e. labour, equipments and machinery as described above.
16.30 PREMIX CARPET WITH HOT BITUMEN OF PAVING ASPHALT GRADE VG- 10/ VG-30
16.30.0 This type of treatment is normally applied on roads where the motor traffic is of medium
intensity, but bullock cart traffic is fairly heavy. This treatment is suitable for district roads and for
internal and service road in colonies. The consolidated thickness of this type of treatment shall be 2
cm or 2.5 cm as specified.
This treatment consists of applying a tack coat on the prepared base followed immediately by
spreading aggregates pre-coated with specified binder to camber and consolidated.
Premix carpet shall not be laid during rainy weather or when the base course is damp or wet or,
when the atmospheric temperature in the shade is not more than 16oC.

This shall be done as described in 16.26.
16.30.2 Materials
Grading of stone chipping shall be as per Table 16.17. Binder shall be as specified in nomenclature
of item and shall conform to Table 16.7. Quantities of materials shall be as given in Table 16.18. A
proper record shall be kept to ensure that the daily out turn of work is correlated with the quantity of
bitumen used as per proforma given in Appendix ‘A’.
TABLE 16.18
Consolidated thickness of Binder Hot Bitumen of Stone Chippings (in cum/ 100 sqm)
premix carpet grade VG- 10/ VG- 30 13.2 mm size 11.2 mm size
(kg/ cum of stone
chipping)
2.00 cm (52 kg/cum of 13.2 mm 1.8 0.90
size and 56 kg per cum of
11.2 mm
2.50 cm -Do- 2.25 1.12

16.30.3 Tack Coat
The rate of application of binder for tack coat shall be as specified in the nomenclature of item.
The rate will be depending upon the surface on which the premix carpet is to be laid i.e. water bound
macadam surface or existing black topped surface. Tack coat shall be applied as described in 16.28.
16.30.4 Preparation of Premix

The aggregate shall be dry and suitably heated to temperature as directed by Engineer-in-
Charge before these are placed in the mixer to facilitate mixing with the binder.
Mixers of approved type shall be employed for mixing the aggregates with the bituminous binder.
The binder shall be heated to the temperature appropriate to the grade of bitumen approved by
the Engineer-in-Charge, in boilers of suitable design avoiding local overheating and ensuring a
continuous supply.
The aggregates shall be dry and suitably heated to a temperature as directed by Engineer-in-
Charge before these are placed in the mixer. After about 15 seconds of dry mixing, the heated binder
shall be distributed over the aggregates at the rate specified.
The mixing of binder with chippings shall be continued until the chippings are thoroughly coated
with the binder. The mix shall be immediately transported from the mixer to the point of use in suitable
vehicles or wheel barrows. The vehicles employed for transport shall be cleaned and be covered
over in transit if so directed.
16.30.5 Spreading and Rolling

The premixed material shall be spread on the road surface with rakes to the required thickness
and camber or distributed evenly with the help of a drag spreader, without undue loss of time. The
camber shall be checked by means of camber boards and inequalities evened out. As soon as
sufficient length of bituminous material has been laid, rolling shall commence with 6 to 9 tonne power
rollers, preferably of smooth wheel tandon type, or other approved power roller. Rolling shall begin
at the edges and progress towards the centre longitudinally. Except on the super elevated portions
rolling shall progress from the lower to upper edge, parallel to the centre line of the pavement. The
consolidated thickness shall not at any place be less than the specified thickness by more than 25%.
However, the average thickness shall not be less than that specified in the item.
When the roller has passed over the whole area once, any high spots or depressions which
become apparent shall be corrected by removing or adding premixed materials. Rolling shall then be
continued until the entire surface has been rolled to compaction and all the roller marks eliminated.
In each pass of the roller, preceding track shall be overlapped uniformly by at least 1/3 width. The
roller wheels shall be kept damp to prevent the premix from adhering to the wheels and being picked
up. In no case shall fuel/lubricating oil be used for this purpose.
Rollers shall not stand on newly laid material as it may get deformed thereby.
The edges along and transverse of the carpet, laid and compacted earlier shall be cut to their full
depth so as to expose fresh surface which shall be painted with a thin surface coat of appropriate
binder before the new mix is placed against it.
Further, the prepared finished surface shall be protected from traffic for 24 hours or such period
as may be directed by the Engineer-in-Charge.

16.30.6 Surface Finishing
The surface regularity both in longitudinal and transverse directions shall be within the tolerances
specified in Table 16.19.
TABLE 16.19
Longitudinal profile Max. permissible Cross profile Max. permissible variation
undulation when measured with 3 M from specified profile when measured
straight edge with a camber template
10 mm 6 mm
The longitudinal profile shall be checked during rolling with a three metres long straight edge and
graduated wedge at the middle of each traffic lane along the road. Similarly the transverse profile
shall be checked with adjustable templates at intervals of 10 metres.
16.30.7 Rectification
Where the surface irregularity fall outside the specified tolerances limit the contractor shall be
liable to rectify it to the satisfaction of Engineer-in-Charge by adding fresh material and recompacting
to specifications where the surface is low. Where the surface is high the full depth of the layer shall
be removed and replaced with fresh material and compacted to specifications.
The length and width of the finished work shall be measured correct to a cm along the finished
surface of the road. The area shall be calculated in square metre, correct to two places of decimal.
For record purposes, the measurement for binder and stone chippings shall be taken as specified
in 16.4.2.2 and 16.4.3.2 before they are actually used on the work. Premeasurements of the materials
taken for record purposes shall simply serve as a guide and shall not form the basis for payment.
16.30.9 Rate
The rate shall include the cost of materials, machinery and labour involved in all the operations
described above for the particular item, except for the cost of Repairs described under para 16.24.2(a).
16.31 PREMIX CARPET WITH BITUMEN EMULSION

16.31.0 This type of work is not ordinarily recommended but may be done in case of urgent repairs
under damp conditions.
16.31.1 Materials
Binder shall be as specified and shall conform to RS grade as per IS 8837 grading of 11.2 mm
stone chipping shall be as per Table 16.17. Quantities of bitumen emulsion and stone chippings shall
be as specified in Table 16.20. A proper record shall be kept to ensure that the daily out turn of work
is corre-lated with the quantity of bitumen used as per proforma given in Appendix ‘A’.
TABLE 16.20
Bitumen Emulsion
Consolidated thickness of Bitumen Emulsion (medium setting Stone Chippings
premix Carpet minimum 65% bitumen content)
For Carpet in kg/cum of chippings cum per 100 sqm
2 cm 96 2.4 (11.2 mm nominal size)
2.5 cm 96 3.0 (11.2 mm nominal size)

16.31.2 Preparation of surface and binder application shall be as specified under 16.26 except that
the rate of application of bitumen for tack coat shall be 0.75 kg per sqm on water bound macadam
surface and 0.5 kg per sqm on black topped surface.
16.31.3 Preparation, spreading, consolidating mix, surface finishing, measurements and rate shall
be as specified under 16.30 except that the bitumen emulsion shall not be heated but it shall be
poured over the aggregate at atmospheric temperature at the correct rate before spreading on the
road surface. The rolling with road roller of 6 to 9 tone capacity shall commence 24 hours after
spreading the mixture. The surface shall be protected by a suitable device such as barricading and
posting of watchmen for closing the traffic.
16.32 BITUMINOUS PENETRATION MACADAM

16.32.0 Scope
The work shall consist of construction of one or more layers of compacted crushed coarse
aggregates with alternate applications or bituminous binder and key aggregates in accordance with
the requirements of these specifications to be used as a base course on roads, subject to the
requirements of the overall pavement design, in conformity with the lines, grades and cross-sections
shown on the drawings or as directed by the Engineer-in-Charge. Thickness of an individual course
shall be 50 mm or 75 mm or otherwise as specified.
16.32.1 Materials
16.32.1.1 Bitumen : The binder shall be paving bitumen of specified penetration grade conforming
to IS 73 or approved cutback satisfying the requirement of IS 217 or 454 as specified in item. The
actual grade of bitumen or cutback to be used shall be as specified in item or as directed by the
Engineer-in-charge.
16.32.1.2 Aggregates: The coarse aggregates shall consist of crushed rock, crushed gravel or
other hard material retained on the 2.36 mm IS sieve. They shall be clean, hard, durable, of cubical
shape, free from dust and soft or friable matter, organic or other deleterious matter. Where the
contractors selected source of aggregate have poor affinity for bitumen, as a condition for approval
of the source, the bitumen shall be treated with approved anti-stripping agents, as per the
manufacturers recommendations, without additional payment. Before approval of the source the
aggregate shall be tested for stripping. The coarse aggregate shall conforming to Table 16.31. The
coarse and key aggregates shall conform to the grading given in Table 16.21.
16.32.1.3 Quantities of Material : The quantities of materials used for this work shall be as
specified in Table 16.21.
16.32.2 Construction Operations

16.32.2.1 Weather and Seasonal Limitations: Laying shall be suspended while free standing water
is present on the surface to be covered, or during rains, fog and dust storm. After rain, the bituminous
surface, tack coat shall be blown off with a high pressure of air jet to remove excess moisture, or the
surface left to dry before laying shall start. Laying of bituminous mixture shall not be carried out when
the air temperature at the surface on which it is to be laid is below 10°C.
16.32.2.2 Equipment : A mechanical broom, compressor, self propelled or trailed bitumen heater/
distributor, mechanical aggregate spreader and 8 to 10 tonne smooth steel wheel roller or vibrating
roller are required for the preparation of Penetration Macadam.
16.32.2.3 Preparation of the Base : The base on which the Penetration Macadam Course is to be
laid shall be prepaid, shaped and compacted to the specified lines, grades and sections as appropriate
or directed by Engineer-in-Charge. A prime coat, where specified shall be applied over the base as
directed by the Engineer-in-charge.

16.32.2.4 Spreading Coarse Aggregate : The coarse aggregate shall be dry and clean and free from
dust, and shall be spread uniformly and evenly at the rate specified in Table 16.21. It shall be spread by
a self-propelled or tripper tail mounted aggregate spreader capable of spreading aggregate uniformly
at the specified rates over the required widths. The surface of the layer shall be carefully checked with
camber templates to ensure correct line and level and cross fall. The spreading shall be carried out
such that the rolling and penetrating operations can be completed on the same day. Segregated
aggregates or aggregates contaminated with foreign material shall be removed and replaced.
TABLE 16.21
Composition of Penetration Macadam
IS Sieve Cumulative percent by weight of total aggregate passing
Designation (mm) For 50 mm compacted Thickness For 75 compacted Thickness
Coarse Aggregate Key Aggregate Coarse Aggregate Key Aggregate
(1) (2) (3) (4) (5)

63 - - 100 -
45 100 - 58-82 -
26.5 37-72 - - 100
22.4 - 100 5-27 50-75
13.2 2-20 50-75 - -
11.2 - - - 5-25
5.6 - 5-25 - -
2.8 0-5 0-5 0-5 0-5
Approx. Loose
Aggregate 0-06 0.015 0.09 0.018
quantities cm/m2
Binder Quantity
As specified
(Penetration As specified in item
in item
Grade)(1) (Kg./m2)
Note : (1) If cutback bitumen is used, adjust binder quantity such that the residual bitumen is
equal to the values in this table.
16.32.2.5 Compaction : After the spreading of course aggregates, dry rolling shall be carried out
with an 8-10 tonne smooth steel wheel roller. After initial dry rolling the surface shall be checked with
a crown and 3 metre straight edge. The surface shall not vary more than 10 mm from the template or
straight edge. All surface irregularities exceeding the above limit shall be corrected by removing or
adding aggregate as required the rolling shall continue until the compacted coarse aggregate has a
firm surface, true to cross-section shown on the plans and has a texture that will allow free and
uniform penetration of the bitumen material.
Compaction shall be done as per following procedure.
Bituminous materials shall be laid and compacted in layers which enable the specified thickness,
surface level, regularity requirements and compaction to be achieved.
Compaction of bituminous materials shall commence as soon as possible after laying. Compaction
shall be substantially completed before the temperature falls below the minimum rolling temperatures
stated in the relevant part of these specifications. Rolling of the longitudinal joints shall be done
immediately behind the paving operation. After this, rolling shall commence at the edges and progress
towards the centre longitudinally except that on super elevated and uni-directional cambered portions,
it shall progress from the lower to the upper edge parallel to the centre line of the pavement. Rolling

shall continue until all roller marks have been removed from the surface. All deficiencies in the
surface after laying shall be made good by the attendants behind the paver, before initial rolling is
commenced. The initial or breakdown rolling shall be done with 8-10 tonnes dead weight smooth-
wheeled rollers. The intermediate rolling shall be done with 8-10 tonnes dead weight or vibratory
roller or with a pneumatic tyred roller of 12 to 15 tonnes weight having nine wheels, with a type
pressure of at least 5.6 kg/sqcm. The finish rolling shall be done with 6 to 8 tonnes smooth wheeled
tandem rollers.
Where compaction is to be determined by density of cores the requirements to prove the

performance of rollers shall apply in order to demonstrate that the specified density can be achieved.
In such cases the Contractor shall nominate the plant, and the method by which he intends to achieve
the specified level of compaction and finish at temperature above the minimum specified rolling
temperature. Laying trials shall then demonstrate the acceptability of the plant and method used.
Bituminus materials shall be rolled in a longitudinal direction, with the driven rolls nearest the
paver. The roller shall first compact material adjacent to joints and then work from the lower to the
upper side of the layer, overlapping on successive passes by at least one-third of the width of the
rear roll or, in the case of a pnueumatic-tyred roller, at least the nominal width of 300 mm.
In portions with super-elevated and uni-directional camber, after the edge has been rolled, the
roller shall progress from the lower to the upper edge.
Rollers should move at a speed of not more than 5 km per hour. The roller shall not be permitted
to stand on pavement which has not been fully compacted, and necessary precautions shall be
taken to prevent dropping of oil, grease, petrol or other foreign matter on the pavement either when
the rollers are operating or standing. The wheels of rollers shall be kept moist with water and the
spray system provided with the machined shall be in good working order, to prevent the mixture from
adhering to the wheels. Only sufficient moisture to prevent adhesion between the wheels of rollers
and the mixture should be used. Surplus water shall not be allowed to stand on the partially compacted
pavement.
After initial dry rolling, the surface shall be checked with a crown template and a 3 metre
straight-edge. The surface shall not vary more than 10mm from the template or straight-edge. All
surface irregularity exceeding the above limit shall be corrected by removing or adding aggregates
as required.
The rolling shall continue until the compacted coarse aggregate has a firm surface true to the
cross section shown on the plans and has a texture that will allow free and uniform penetration of the
bitumen material.
16.32.2.6 Application of Bituminous Material : After the coarse aggregate has been rolled and
checked, the bituminous binder shall be applied at the rate given in Table 16.21, at a temperature
directed by Engineer-in-Charge.
At the time of applying the binder, the aggregates shall be surface dry for the full depth of the layer.
In certain circumstances, depending on the type and size of aggregate used, the Engineer-in-
Charge may direct the placing of a bed of clean sand or quarry fines, not exceeding 10 mm in
thickness, on the prepared foundation before placing the coarse aggregate. The sand or fine material
shall be slightly wetted, just sufficient for it to slurry up during the compaction process. Where cut
back is used, if flooding of the binder occurs it should be applied in two operations, or as directed by
the Engineer-in-charge.

16.32.2.7 Application of Key Aggregates : Immediately after the first application of bitumen, the key
aggregates, which shall be clean, dry and free from dust shall be spread uniformly over the surface
by means of an approved mechanical spreader or by approved manual methods at the rate specified
in Table 16.21.
Where directed by the Engineer-in-charge, the surface shall be swept and the quantity of key
aggregate adjusted to ensure uniform application, with all the surface voids in the coarse aggregate
being filled without excess. The entire surface shall then be rolled with a 8- 10 tonnes smooth steel
wheel roller (or vibrating roller operating in non-vibratory mode) in accordance with the procedure
specified in above para 16.32.2.5.
16.32.3 Surface Finish and Quality Control

The surface finish of the completed construction shall conform to the requirements of section
900 of MORTH specifications. For control of the quality of materials supplied and the works carried
out the relevant provisions of Section 900 of MORTH specifications.
16.32.4 Surfacing
The penetration Macadam shall be provided with a surfacing (binder/wearing course) within a
maximum of forty-eight hours. If there is to be any delay, the penetration macadam shall be covered
by a seal coat as specified and directed by Engineer–in-charge. The seal coat in such cases shall be
considered incidental to the work and shall not be paid for separately.
16.32.5 Arrangements for Traffic

During the period of construction, arrangements for traffic shall be made in accordance with the
provisions of specification and as per direction of Engineer-in-Charge.
16.32.6 Measurement for Payment

Penetration Macadam base course shall be measured as finished work in square metres.
16.32.7 Rate
The rate includes the cost of all materials, labours and equipment involved in all the operations
described above.
16.33 BITUMEN MASTIC WEARING COURSES

16.33.1 Definition
The bitumen mastic is an intimate homogeneous mixture of mineral fillers and well graded fine
and coarse aggregates with a hard grade bitumen, cooked and laid hot, troweled and floated by
means of a wooden float. The mixture settles to a coherent, void less and impermeable solid mass
under normal temperature conditions.
The bitumen mastic is normally used as a wearing course. Over the mastic laid surface, hard
stone chips pre-coated with bitumen are grafted or spread and rolled to provide a skid resistant
surface.
Bitumen mastic is used as a wearing course in different situation of heavy duty road pavements.
However, use of this material is not recommended in places where abundant fuel oil dripping is
expected on the pavement surfaces like bus depots, fuel filling and service stations etc.
16.33.2 Materials
16.33.2.1 The bitumen shall be industrial bitumen conforming to IS 702 of grade 85 /25 or suitable
consistency satisfying the requirements of physical properties as given in Table 16.22.

TABLE 16.22
Physical Properties of Bitumen
S.No. Characteristics Requirements Method of Test
1. Penetration at 25 deg. C in 1/10 mm 15 ± 5 IS 1203
2. Softening point (R&B) 65 ± 10 IS 1205
3. Ductility at 27 deg.C (Minimum in cms.) 3 IS 1208
4. Loss on heating, per cent (Maximum) 2 IS 1212
5. Solubility in trichloroethylene per cent by 95 IS 1216
mass (minimum)
6. Ash (mineral matter) %age by mass 1.0 IS 1217
16.33.2.2 Coarse Aggregates : The coarse aggregates shall consist of clean, hard, durable, crushed
rock free of disintegrated pieces, organic and other deleterious matter and adherent coatings. They
shall be hydrophobic, of low porosity, and satisfy the physical requirements set forth in Table 16.23.
TABLE 16.23
Physical Requirements of Coarse Aggregates for Bitumen Mastic
S.No Test Test Method Acceptance Criteria

(a) Los Angeles Abrasion Value IS 2386 (Pt.4) 40% (Max.)
or -do- or
1. (b) Aggregate impact value 30% (Max.)
2. Flakiness Index IS 2386 (Pt.1) 30% (Max)
3. Stripping Value IS 6241 25% (Max)
4. Soundness
(i) Loss with Sodium Sulphate 5 cycles IS 2386 (Pt.5) 12% (Max)
(ii) Loss with Magnesium Sulphate 5 -do- 18%(Max)
cycles
5. Water Absorption IS 2386 (Pt.3) 2% (Max)
6. Retained tensile strength - 80% (Min)
The percentage and grading of the coarse aggregates to be used in the bitumen mastic
depending upon the thickness of the finished course shall be as in Table 16.24. The minimum and
maximum thickness of the bitumen mastic for wearing course shall be 25 mm and 50 mm respectively
except for footpaths of bridges where it shall be 20 mm and 25 mm respectively.
TABLE 16.24
Grading and Percentage of Coarse Aggregates for Bitumen
Mastic in Wearing Course and Footpath
S. No Type of work Grading of coarse Thickness of Percentage of coarse
aggregate finished mastic aggregates(mm)
%age surface course
passing IS
IS Sieve sieve
1. Wearing course for road 19 mm 100 (a) 25-40 (a) 30-40
pavement and bridge 13.2 mm 88-96 or or
decks (b) 41-50 (b) 40-50
2.36 mm 0-5
2. Footpaths 6.7 mm 100 20-25 15-30
600 micron 0.15
16.33.2.3 Fine Aggregates : The fine aggregates shall consist of crushed hard rock or natural sand or a
mixture of both. The grading of fine aggregates inclusive of filler material passing 75 micron shall be as given
in Table 16.25.

TABLE 16.25
Grading of Fine Aggregate I/C Filler
Passing IS Sieve Retained on IS Sieve % age by Weight

2.36 mm 600 micron 0-25
600 micron 212 micron 10-30
212 micron 75 micron 10-20
75 micron — 30-50
16.33.2.4 Filler : The filler shall be limestone powder passing 75 micron and shall have a calcium carbonate
content of not less than 80 per cent when determined in accordance with IS 1514.
16.33.3 Equipment for Bitumen Mastic

16.33.3.1 There are two ways of preparing a mastic. The conventional method is by using a mastic cooker
which is dealt with in this specification. The other method using fully mechanized units needed for large scale
work, as is generally practiced in Germany (Gussasphalt), may form the subject of a separate document.
16.33.3.2 Mastic cooker are very similar to tar boilers. These are insulated tanks mounted on wheeled
chassis. The heating of the bitumen and material is generally done by oil fired burners. Mastic cookers have
compartments. The central and main compartment is used for heating bitumen and for preparing the mix. The
side pockets or compartments are meant for pre-heating of the coarse and fine aggregates. Since heating is
by oil fired burners, the temperature can be easily controlled by controlling the flames or supply of the fuel.
16. 33.3.3 Mastic cookers of various capacities ranging from 1/2 tonne to 3 tonne are used depending on the
amount of work involved. These are not being marketed commercially because it is not a common specification
but can be easily got made from manufactures of tar boilers.
Fig. 16.13 indicates the broad details of equipment and components of cooker presently in common use.
16.33.3.4 Apart from mastic cooker, the following equipments are required for transportation and laying.
(1) Wheel barrows and flat mortar pans (for short distance haul) and small dumpers (for long distance haul).
(2) Wooden trowels, heavy wooden floats, suitable hand tools gauge, straight edge and hand level.
(3) Angle irons, required to contain the mastic in desired width and thickness.
16.33.4 Manufacture of Bitumen Mastic

16.33.4.1 The manufacture of bitumen mastic involves different stages. Initially the filler alone shall be heated to
a temperature of 175 deg. C to 210 deg. C in mechanically agitated mastic cooker and half the required quantity
of bitumen heated at 175 deg. C to 180 deg. C added. They shall be mixed and cooked for one hour. After that
the fine aggregates and the balance bitumen at 175 deg. C to 180 deg. C shall be added to that mixture in the
cooker and heated upto 175 deg. C to 200 deg. C and further mixed for another one hour. In the final stage, the
coarse aggregates shall be added and heating of mix shall continue for another one hour. Thus a total period of
minimum three hours will be needed to prepare the mastic. During mixing and cooking, care shall be taken to
ensure that the contents in the cooker are at no time heated to a temperature exceeding 210 deg. C.
16.33.4.2 In case the material is not required for immediate use, the bitumen mastic with filler, fine aggregates
and bitumen shall be cast into blocks each weighing about 25 kg. The bitumen mastic blocks (without coarse
aggregates) shall show on analysis a composition with the limits as given in Table 16.26. These blocks when
intended to be used subsequently shall be transported to site, broken into pieces of size not exceeding 60
mm cube and remelted in the cooker at a temperature ranging from 175 deg. C. to 210 deg. C thoroughly
incorporating the requisite quantity of coarse aggregates as indicated in Table 16.26 and mixed continuously
for at least an hour. Mixing shall be continued until the laying operations are completed so as to maintain the
coarse aggregates in suspension. At any stage the temperature during the process of mixing shall not
exceed 210 deg. C.

TABLE 16.26
Composition of Bitumen Mastic Blocks without Coarse Aggregates
IS Sieve % age by weight
Passing Retained Minimum Maximum
2.36 mm 600 micron 0 22
600 micron 212 micron 4 30
212 micron 75 micron 8 18
75 micron - 25 45
Bitumen content 14 17
16.33.5 Hardness Number

The hardness number of bitumen mastic shall be determined at 25 deg. C in accordance with IS
5317and with the method specified in Appendix D of IS 1195. It shall conform to the following
requirements:
(1) Without coarse aggregates at 25 deg. C 60-80
(2) With coarse aggregates at 25 deg. C 10-20
16.33.6 Laying the Bitumen Mastic

16.33.6.1 Preparation of the Base : The base on which bitumen mastic is to be laid shall be prepared,
shaped and conditioned to the specified levels, grade and camber as directed. If the existing surface
is too irregular and wavy, it shall be made good by providing a corrective course of bituminous
concrete mix as per IRC:29. The surface shall be thoroughly swept clean and made free of dust and
other dele-terious matter. Spots rich in binder shall be scrapped and repaired. Under no circumstances
the bitumen mastic sheet be spread on a base containing a binder which will soften under high
application of temperature. If any such spot exists, the same shall be cut out and repaired before the
bitumen mastic is laid. To receive and contain the mastic, angle irons of sizes 25 or 50 mm are placed
at required spacing till finish of the job.
16.33.6.2 Transportation of Mix : When the bitumen mastic, duly prepared including addition of
coarse aggregates at the manufacturing point, is to be transported over a long distance and delivered
to the laying site, arrangements for transport shall be made in a towed mixer transporter with adequate
provision for heating and stirring so as to keep the aggregates and filler suspended in the mix till the
time of laying. However for small works and where the laying site is near the manufacturing point, the
mix can be transported in wheel barrows/flat mortar pans. To prevent the molten material from sticking
to the wheel barrows/pans, the inside of the transport may be sprinkled with a minimum quantity of
inorganic fine material like limestone dust. However, cement, ash or oil shall not be used.
16.33.6.3 Laying of Mix

16.33.6.3.1 The bitumen mastic shall be discharged into containers sprinkled with limestone dust or
provided with lime-wash. The bitumen mastic shall be deposited directly on the prepared base
immediately in front of the spreader where it is spread uniformly by means of wooden floats to the
required thickness. The mix shall be laid in one metre widths confined between standard angle irons
of size 25 mm to 50 mm to receive and contain the mastic of required thickness. The temperature of
the mix at the time of laying shall be 175 deg. C. In case blowing takes place while laying the bitumen
mastic, the bubbles shall be punctured while the mastic is hot and the surface made good. Since
mastic asphalt is an expansive material, extreme care shall be taken while fixing the angle irons and
their level checked with instrument at suitable intervals.
16.33.6.3.2 Laying Bitumen Mastic Surfacing over Old Existing Bridge Deck : Before laying bitumen
mastic over old existing bridge deck, the existing cross fall/camber, expansion joint members and water
drainage spouts shall be carefully examined for their proper functioning in the bridge deck structure
and any deficiency found shall first be removed. Loose elements in the expansion joint shall be firmly
secured. The cracks in the concrete surface, if any, shall be repaired and filled up properly or replaced
by new concrete of specified grade before laying the bitumen mastic over bridge deck.

16.33.6.3.3 Laying over New Bridge Deck : New concrete bridge deck which is not in camber/cross fall shall
first be provided with required camber and cross fall by suitable concrete or bituminous treatment. In case of
laying over concrete surface, following measures shall be taken:
(1) For proper bond with new concrete deck, surface shall be roughened by means of stiff broom or
wire brush and it shall be free from ridges and troughs.
(2) A thin bituminous tack coat (with bitumen of grade 80/100) shall be applied on the concrete deck
before pouring mastic. The quantity of bitumen for tack coat shall not exceed 5-6 kg per 10 sqm.
(3) On surface in longitudinal slope, after applying tack coat, chicken-mesh reinforcement of 1.5 mm
dia steel wire with hexagonal or rectangular openings of 20-25 mm shall be placed and held properly
in position on the concrete surface before pouring mastic.
16.33.7 Joints
All construction joints shall be properly and truly made. These joints shall be made by warming the
existing bitumen mastic by the application of an excess quantity of hot bitumen mastic which afterwards
shall be trimmed off to make it flush with surface on the either side.
16.33.8 Surface Finish

The bitumen mastic surfacing has got a very fine texture which on initial laying provides very little resistance
to skidding. Therefore, the bitumen mastic after spreading and while still hot and in plastic condition shall be
spread over with bitumen precoated fine grained hard stone chips/aggregates of approved quality of 13.2 mm
size complying with quality requirement as per Table 16.27 depending upon the thickness of mastic, using
bitumen at the rate of 2 to 3 percent of S-65 or S-90 grades and aggregates at the rate of 0.005 cum (1/200
cum) per 10 sqm. and at a spacing of 10 cm c/c in both directions and pressed into the surface when the
temperature of bitumen mastic is between 80 deg. C. and 100 deg. C. Such precoated aggregates when laid
should protrude 2 to 4 mm over the mastic surface. Flakiness index of stone aggregates used for anti-skid
measures shall be less than 25 per cent. The addition of 2% filler complying with Table 16.28/16.30 may be
required to enable the quantity of bitumen to be held without draining.
TABLE 16.27
Sl.No. Name of Test I.S.Code Acceptance Criteria
1. Grain size analysis IS 2386 Part 1 Max. 5% passing IS
sieve 75 micron
2. Flakiness or elongation Index IS 2386 Part 4 Max. 30% *
3. Los Angeles Abration Value -do- Max. 30%
4. Polished Stone Value B.S. 812 (Part 114) Min. 55
5. Soundness
(a) Sodium Sulphate IS 2386 (Part 5) Max. 12%
(b) Magnesium Sulphate Max. 18%
6. Water absorption IS 2386 Part 3 Max. 2%
7. Coating and stripping of bitumen IS 6241 Min retained coating
aggregate mixture 95%
8. Water sensitivity retained tensile AASHTO T 283 Min. 80% **
strength
* The elongation test to be done only on non-flaky aggregate to the sample.

** This test is only required if the maximum retained coating in the stripping test is less than 95%.
TABLE 16.28
Sl. No. IS Sieve (MM) Cummulative percent passing
by weight of total aggregate
1. 0.6 100
2. 0.3 95-100
3. 0.075 85-100
The traffic may be allowed after completion of work when the bitumen mastic has cooled down to
the ambient temperature.

16.33.9 Controls
16.33.9.1 Sieve analysis of each type of the aggregate used shall be made at least once a day to
see that the gradation of the aggregates follows the original gradation as approved. Additional tests
shall be carried out in case of variation in grading or receipt of supply of material from new source.
The number of samples to be tested per day would depend upon the bulk supply of aggregates
made in a day at the plant site. Physical properties such as aggregate impact values, flakiness index,
water absorption etc. shall be determined at the rate of one test for every 25-50 cum of aggregates
or as directed by the Engineer at site.
16.33.9.2 Two sets of test shall be carried out on each lot of supply of bitumen for checking penetration
and softening point as per IS 1203 and IS 1205.
16.33.9.3 For filler material calcium carbonate content and fineness shall be tested at the rate of one
set of tests for each consignment subject to a minimum of one set of test per 5 tonne or part thereof.
16.33.9.4 It shall be ensured that the aggregates are not wet before heating, otherwise it would
affect the output adversely. During heating the aggregate temperature shall be recorded periodically
to see that it does not exceed the limits prescribed.
16.33.9.5 Material in block form shall be sampled by taking approximately equal amount in pieces,
from not less than six blocks chosen at random. The total weight of specimen to be tested shall not
be less than 5 kg. In case the preparation of the mix is at site, then at least one sample of every 10
tonne of bitumen mastic discharged from the mastic cooker or at least one sample for each cooker
per day shall be collected and following tests done:
(1) Two specimens each of 10 cm dia or 10 cm square and 2.5 cm thick shall be prepared and
tested for hardness number.
(2) Bitumen shall be extracted from about 1000 gm of the mastic sample and bitumen content
determined as specified in Appendix C of IS 1195.
(3) A sieve analysis of the aggregates after the bitumen is extracted, shall be done and the
gradation determined according to the procedure laid down in IS 2386 (Pt.I).
16.33.9.6 The temperature of the bitumen mastic at the time of laying shall not exceed 210 deg. C
and shall not be less than 175 deg. C.
16.33.9.7 The longitudinal profile of the finished surface shall be tested with a straight edge 3 m long
and transverse profile with a camber template while the mastic laid is still hot. Irregularities greater
than 4 mm in the longitudinal and transverse profile shall be corrected by picking up the mastic in full
depth and full area of the affected panel and relaying.
16.33.9.8 Bitumen mastic shall not be laid on a damp or wet surface or when the atmospheric
temperature in the shade is 15 deg. C or less.
The length & breadth of the area where bitumen mastic wearing course of specified thickness
has been provided shall be measured correct to a centimeter and the area shall be calculated in
square metres correct to two decimal places.
16.33.11 Rate
The rate per square metre shall include cost of all the operations described above including anti-
skid treatment mentioned in para 16.33.1 above.

16.34 BITUMINOUS SHEET WITH HOT BITUMEN
16.34.0 This type of treatment is normally done for garden paths, driveways, footpaths and
playgrounds and roads. The treatment is also useful in providing a thin wearing course over existing
cement concrete roads. This is sometimes capable of standing with very heavy traffic. This can also
be used over worn out cement concrete pavements, the concrete surface is roughened before
laying the binder coat. It is also useful as a corrosion resistant flooring in shade and godowns for
storing salt, fertilizer etc. This treatment consists of a mixture of coarse sand and stone chippings
with bituminous binder, spread and consolidated to a specified thickness on prepared surface after
the application of a tack coat.
The consolidated thickness of this type of treatment shall be 2.5 cm or 4 cm, as specified.
The work shall be carried out only when the atmospheric temperature in shade is 16 deg. C or
above. No bituminous material shall normally be applied when the road surface or material is damp
or when the weather is foggy or rainy, or during dust storms. Bitumen of specified grade and
consistency to be used.
16.34.1 Quantities of Materials

The quantities of materials shall be as specified in Table 16.29.
TABLE 16.29
Consolidated Bitumen VG- 10/ VG-30/ Refinery modified bitumen Stone chippings Coarse sand
thickness of (RMB 55) cum/100 sqm of cum/100 sqm of
bituminous sheet Kg/sqm of Kg/cum of stone Kg/cum of road surface road surface
surface area chipping sand
(For Tack
Coat)
2.5 cm 0.75 56 128 1.65* 1.65
4 cm 0.75 56 128 2.60* 2.60
* 60% with 12.5 mm Nominal size and
* 40% with 10 mm Nominal size
A proper record shall be kept to ensure that the daily turn out of work is corelated with the
quantity of bitumen used as per proforma prescribed in Appendix ‘A’ .
16.34.2 Preparation of surface and application of binder (tack coat ) shall be as specified under
16.28.2 to 16.30.5.
16.34.3 Preparation of Mix, laying and Consolidation

Para 16.30.4 and 16.30.5 shall generally apply except that the mixing shall be done in two stages.
Stone aggregate of the correct standard size and in the proportion shown in table 16.29 shall be fed
into the mixer to which 2/3 rd of the total specified quantity of bitumen heated to the appropriate
temperature shall be added. When the stone metal is well coated, the sand in the specified proportion
and then the balance 1/3rd quantity of total bitumen shall be fed into the mixer. Mixing shall be
continued until a homogeneous mix is produced and all particles are uniformly coated with bitumen.
Any high spots or depressions which become apparent shall be corrected by addition or removal
of premixed materials. The rolling shall continue until the maximum consolidation to the satisfaction
of Engineer-in -Charge is obtained. The wheels of the roller shall be moistened with gunny bags to
prevent the mixture from sticking to the wheel while rolling.

16.34.4 Surface finishing and rectification shall be as specified under 16.30.6 and 16.30.7.
16.34.5 Permitting Traffic

Traffic shall be allowed on the road after a lapse of 24 hours to 48 hours after laying, as decided
The length and width of the finished work shall be measured correct to a cm along the finished
surface of the road. The area shall be calculated in square metre, correct to two places of decimal.
For record purposes measurements for binder, stone aggregate, stone chippings and sand as
described under 16.3 shall be taken before they are actually used on the work. Premeasurements shall
simply serve as a guide and shall not form the basis for payment. The thickness of surface treatment shall
be the ruling criterion for payment.
16.34.7 Rate
above.
16.35 SEAL COAT

16.35.1 Scope
This work shall consist of the application of a seal coat for sealing the voids in a bituminous
surface laid to the specified levels, grade and cross fall (camber).
16.35.2 Seal coat shall be of either of the two types specified below:
(A) Liquid seal coat comprising of an application of all layer of bituminous binder followed by a
cover of stone chips.
(B) Premixed seal coat comprising of a thin application of the aggregate premixed with bituminous
binder.
16.35.3 Materials
16.35.3.1 Binder : The binder and its quantity shall be a penetration bitumen of a suitable grade
as specified in the item or as directed by the Engineer-in-charge.
16.35.3.2 Stone Chips for Seal Coat : The stone chips shall consist of angular frangments of
clean, hard, tough and durable rock of uniform quality throughout. They should be free of soft or
disintegrated stone, organic or other deleterious matter. Stone chips shall be of 6.7 mm size defined
as 100 per cent passing through 11.2 mm sieve and retained on 2.36 mm sieve. The quantity used
for spreading shall be 0.09 cubic metre per 100 square metre area. The stone chips shall satisfy the
quality requirements in Table 16.31 bituminous except that the upper limit for water absorption value
shall be 1 per cent.
TABLE 16.30
Sl. No. I.S. Sieve (mm) Cumulative % passing by weight of total aggregate
1. 0.6 100
2. 0.3 95-100
3. 0.075 85-100
1. Grain size analysis IS 2386 Part I Max 5% passing IS sieve 75 micron

2. SPECIFICATIONS
CPWD Flakiness and2019
elongation IS 2386 806
(Part IV) Max 30%
3. Los Angeles Abration IS 2386 (Part IV) Max 30%
4. Polished stone value B.S. 812 (part 114) Min 55%

5. Soundness IS 2386 (Part V)
(a) Sodium sulphate Max 12%
TABLE 16.30
Sl. No. Name of Test I.S. Code Acceptance Criteria

1. Grain size analysis IS 2386 Part 1 Max 5% passing IS sieve 75 micron
2. Flakiness and elongation IS 2386 (Part 4) Max 30%
Index
3. Los Angeles Abration IS 2386 (Part 4) Max 30%
Value
4. Polished stone value B.S. 812 (part 114) Min 55%
5. Soundness IS 2386 (Part 5)
(a) Sodium sulphate Max 12%
(b) Magnesium sulphate Max 18%
6. Water absorption IS 2386 (Part 3) Max 2%
7. Coating and stripping of IS 6241 Min retained coating 95%
Bitumen aggregate
mixture
8. Water sensitivity AASHTOT 283 Min 80%
retained tensile strength
* The elongation test to be done only on non-flaky aggregate on the sample.
** This test is only required if the minimum retained coating in the stripping test is less than 95%.
16.35.3.3 Fine Aggregate : The aggregate shall be sand or grit and shall consist of clean, hard
durable, uncoated dry particles and shall be free from dust, soft or flaky/elongated material, organic
matter or other deleterious substances. The aggregate shall pass 2.36 mm sieve and be retained on
180 micron sieve. The quantity used for premixing shall be 0.06 cubic metres per 100 square metres
area. Stones or fine aggregate shall be used as specified in item.

16.35.4.1 Weather and Seasonal Limitations : Ref. Item No. 16.32.2.1.
16.35.4.2 Preparation of Surface : The seal coat shall be applied immediately after laying the
bituminous course which is required to be sealed. Before application of seal coat materials, the
surface shall be cleaned free of any dust or other extraneous matter.
16.35.4.3 Construction of Seal Coat with Stone Chips : Bitumen shall be heated to 150oC - 163oC
and sprayed at the rate specified on the dry surface in a uniform manner with a self-propelled
mechanical sprayer
Immediately after the application of binder, stone chips which shall be clean and dry, shall be
spread uniformly at the rate specified on the surface preferably by means of a self –propelled or
towed mechanical grit spreader so as to cover the surface completely. If necessary, the surface shall
be brushed to ensure uniform spread of chips.
Immediately after the application of the cover material, the entire surface shall be rolled with a 8-10
tonne smooth wheeled steel roller, 8-10 tonne static weight vibratory roller, or other equipment approved
by the Engineer after laying trials if required. Rolling shall commence at the edges and progress
towards the centre except in super elevated and unidirectional cambered portions where it shall proceed
from the lower edge to the higher edge. Each pass of the roller shall uniformly overlap not less than
one-third of the track made in the proceeding pass. While rolling is in progress, additional chips shall
be spread by hand in necessary quantities required to make up irregularities. Rolling shall continue
until all aggregate particles are firmly embedded in the binder and present a uniform closed surface.

16.35.4.4 Construction of Seal Coat with Premixed Fine Aggregate : A mixer of appropriate capacity
and type approved by the Engineer-in-charge shall be used for preparation of the mixed material.
The plan shall have separate dryer arrangements for heating aggregate.
The binder shall be heated in boilers of suitable design, approved by the Engineer-in-Charge to
the temperature appropriate to the grade of bitumen or as directed by the Engineer-in -Charge. The
aggregates shall be dry and suitably heated to a temperature between 150oC and 165oC or as
directed by the Engineer-in-charge before these components are placed in the mixer. Mixing of
binder with aggregates to the specified proportions shall be continued until the latter are thoroughly
coated with the former.
The mix shall be immediately transported from the mixing plant to the point of use and spread
uniformly on the bituminous surface to be sealed.
As soon as a sufficient length has been covered with the premixed material, the surface shall be
rolled with an 8-10 tonne smooth-wheeled roller. Rolling shall be continued until the premixed material
completely seals the voids in the bituminous course and a smooth uniform surface is obtained.
16.35.5 Opening to Traffic

In the case of seal coat with premixed fine aggregate traffic may be allowed soon after final rolling
when the premixed material has cooled down to the surrounding temperature. In the case of seal
coat with stone chips traffic shall not be permitted to run on any newly sealed area until the following
day. In special circumstances, however, the Engineer-in-charge may open the road to traffic
immediately after rolling, but in such case traffic speed shall be rigorously limited to 16 km. per hour
until the following day

Seal coat, for both items shall be measured as finished work over the area specified to be covered,
in square metres at the thickness specified in the item.
16.35.7 Rate
The rate for seal coat shall be cost of all materials, labour and equipment involved in operation
described above.
16.36 CEMENT CONCRETE PAVEMENT (UNDER ORDINARY CONDITIONS)

Specifications of item 16.37 to be followed except that cement concrete of grade 1:2:4 or specified
otherwise to be prepared and compacted.
16.37 CEMENT CONCRETE PAVEMENT UNDER CONTROLLED CONDITIONS

16.37.1 Materials
16.37.1.1 Cement
(a) Cement used on work shall be as per sub head cement concrete of CPWD specifications-
2019 (Vol. – I).
16.37.1.2 Water : Water used on work shall conform to SH: cement concrete of CPWD, Specification
2019- Vol. I.
16.37.1.3 Coarse Aggregate : These shall be crushed or broken from hard stones obtained from
approved quarry. These shall be clean strong, durable of fairly cubical shape and free from soft,
friable, thin elongated and laminated disintegrated pieces. These shall also be free from dirt, organic
deleterious and any other foreign matter and adherent coatings and shall satisfy the physical
requirements laid down in para 16.37.19 under quality control.

16.37.1.4 Fine Aggregate : This shall be coarse sand conforming to CPWD Specification 2019 Vol. I.
16.37.1.5 Grading of Mixed Aggregates : The grading of all aggregates (coarse and fine aggregates)
to be used in the work shall be determined in the laboratory. The coarse and fine aggregates shall
be mixed in suitable proportions so that the grading of the mixed aggregates shall be in the range
indicated in Table 16.32.
TABLE 16.32
I.S. Sieve Size (IS 460) % age passing by weight

45 mm 100
22.4 mm 55 - 60
11.2 mm 45 - 50
5.6 mm 35 - 40
2.8 mm 30 - 35
1.4 mm 20 - 25
710 microns 15 - 20
355 microns 10 - 14
180 microns 2-5
16.37.2 Mix Design

16.37.2.1 The mix shall be approved by Engineer-in- Charge so as to obtain the following mean
strength that exceeds the minimum specified flexural strength by 1.64 times the designed standard
deviation.
Minimum works beam
flexural strength at 28 days = 300 kg/sqm. for M-30 or specified in item
Designed standard deviation = 60 kg/sqm. for M-30 or for specified grade(s)
Design flexural strength at 28 days = 300+60x1.64
Water cement ratio by weight = 398.4 kg/sqm. (f + 1.64 s )
says 400 kg.
Water cement ratio by weight = 0.5
Minimum slump not more than 25 mm
16.37.2.2 For the purpose of tendering the contractor shall base his rate on the assumption that the
quantity of cement used for one cum. of finished concrete shall be 340 kg. or M - 30. If the actual
quantity of cement required to be used as a result of the laboratory test is different from that assumed
above, necessary adjustment in the cost due to short cement used shall be made on the basis of
issue rate of cement including storage charges plus 2.5% for handling charges. However, under no
circumstances the quantity of cement to be used shall either exceed 350 kg./cum or fall below 330
kg. per cum of finished concrete.
16.37.3 Statistical Field Check

16.37.3.1 Samples of concrete shall be taken at the mixer and works beams, made, cured and tested
in accordance with IS 1199 and IS 516.
16.37.3.2 When a mix is used for the first time, it is important to get a large number of results, as
soon as possible, in order to establish the level of control and then suitability of the mix proportions.
A sample of concrete shall be taken at random on eight separate occasions during each of the first
five days of using that mix. From each sample two beams shall be made one for test at 7 days and
the other for test at 28 days.

16.37.3.3 The work beam results shall be examined both individually and in consecutive (but not
overlapping) sets of four, for which the average and the range of each set is calculated. The mix
proportions shall be modified to increase the strength, if in the first ten consecutive (but not
overlapping) sets any of the following conditions are not satisfied.
(I) Each sample has a test strength not less than the minimum specified strength i.e. 30 kg/sq.
cm. (or otherwise specified in item).
OR
(II) (a) Not more than two individual results (Not more than one of first twenty) of the 40 beams
tests shall fall below the minimum work beam strength but they shall not be less than
80% of the specified beam strength of 30 kg./sq. cm (or otherwise specified in item) or
the minimum specified strength minus 1.35 times the standard deviation whichever is
greater.
(b) No value of the range in any set shall exceed 3 times the designed standard deviation.
(c) The average for all samples (10 sets) shall not be less than the minimum specified
strength i.e. 30 kg/sq. cm (or otherwise specified in item) plus 1.64 times the designed
standard deviation 60 kg./sq.cm M-30.
16.37.3.4 If either of these conditions (16.37.3.3 I or 16.37.3.3 II) are not satisfied, the mix shall be
modified and the procedure described above shall be repeated till results satisfying the above criterias
are obtained.
16.37.3.5 Subsequently samples shall be taken at the rate of one for every 30 cubic metre of concrete
laid. Eight beam specimen shall constitute one sample. A set of 4 specimen shall be tested after 7
days and another set of 4 specimen shall be tested after 28 days. These test results shall be checked
individually and in sets of four as the work progresses. If at any stage it is found that either of
conditions 16.43.4.3,I or 16.4.3,II are not satisfied, the overall average and the standard deviation of
the previous consecutive 40 beam test results including the non-complying set shall be calculated. If
the overall average strength minus 1.64 times the standard deviation is more than the specified
beam strength (30 kgm/sq.cm) (or otherwise specified in item) the concrete shall be accepted. But if
it is less than the concrete work corresponding to these 40 beams tests shall be rejected and the mix
proportion shall be modified forth with for further work. The rejected work shall be replaced by the
contractor immediately at his own cost and expense.
16.37.3.6 The statistical field checks described in 16.37.3.1 to 16.37.3.2 are meant to control the
quality of concrete. The standard of acceptance of concrete shall be governed by the provision of
para 16.37.3.3 to 16.37.3.5.
16.37.4 Slump Test

The test shall be carried out as per IS 1199. A slump test shall be carried out at each mixer at
least one in fifty batches mixed or more frequently if directed by the Engineer- in-Charge. Any batch
from which slump test is being made shall not be transferred to the place of laying till the slump test
has been completed. Not only the batch which gives a slumps in excess of that specified shall be
rejected but the concrete already laid immediately preceding the batch tested upto the nearest last
transverse joint may be rejected by the Engineer-in-Charge or his subordinate, if he is satisfied that
such preceding batches were substandard in this respect. The decision of the Engineer-in-Charge
in this respect shall be final and binding on the contractor. Such rejected concrete shall be removed
by the contractor immediately and replaced with proper slump concrete at his cost and expense.
16.37.5 Steel Forms

16.37.5.1 All side forms shall be of mild steel. The steel forms shall be of M.S. Channel sections and
their depth shall be equal to the thickness of the pavement.

16.37.5.2 The side forms shall have a length of at least 3.0 metres except on curves of less than 4.5
metres radius where shorter lengths may be used. When set to grade and stacked in place the
maximum deviation of the top surface of any section from a straight line shall not exceed 3 mm. The
method of connection between sections shall be such that the joint formed shall be free from play or
movement in any direction. The use of bent, twisted or worn out forms shall not be permitted. At least
three stake pockets for bracing pins or stakes shall be provided for each 3.0 M length of forms.
Bracing and supports must be ample to prevent the springing of forms under pressure of concrete or
weight or thrust of the machinery (like screed vibrator) operating on the forms. Support to the forms
shall be sufficiently rigid to hold them in position during the entire operation of laying and compacting
and finishing and that they shall not at any time deviate more than 3 mm from straight edge 3 metres
in length. Forms which show a variation from the required rigidity of the alignment and levels shown
on the plans shall be reset or removed as directed. The length and number or pins or stakes shall be
such as to maintain the forms at the correct line and grade.
16.37.5.3 The supply of forms shall be sufficient to permit their remaining in place for at least 12 hrs.
after the concrete has been placed or longer, if in the opinion of the Engineer-in-Charge, it is necessary.
16.37.5.4 The top line of the forms is not to vary from the correct level or alignment and the levels
and alignment of the forms are to be checked and corrected as necessary immediately prior to the
placing of concrete. The top edges and faces of the forms are to be carefully cleaned and maintained
in clean condition.
16.37.5.5 While removing the steel forms, care shall be taken to withdraw them gradually, any damage
to the bull nosed edges shall be made good while the concrete is still green.
16.37.5.6 Setting of Forms

(a) Setting of forms shall be according to the slab plan subject to the approval of Engineer-in-
Charge and concreting shall not commence until the setting of forms is approved.
(b) Forms shall be set for at least 50 metres in advance of the point where the concrete is being
laid and shall not be removed until at least 12 hrs. of placing of the concrete or longer if in
the opinion of Engineer-in-Charge is necessary.
(c) After setting, the working faces shall be thoroughly oiled by using approved oil before
concrete is placed against them.
(d) The pavement joints of overlay layer would overlap with the joints of underlay cement
concrete.
16.37.6 Batching and Mixing

As detailed in SH: 5 of reinforced cement concrete work of CPWD specifications 2019.
16.37.7 Placing of Concrete

As detailed in SH: 5 of reinforced cement concrete work of CPWD specifications 2019.
16.37.8 Compaction of Concrete
16.37.8.1 Compaction shall be carried out by electrically (or) diesel operated needle and screed
vibrators as stipulated hereafter. Needle vibrator should be used all over the area for obtaining initial
compaction of concrete. These should be of diameter not less than 4.5 cm. If the vibrator are pneumatic
the pressure must not be below 4 kg/sq.cm. If electrically operated, they should have a minimum
frequency of 3500 impulses per minute.

16.37.8.2 There should be at least three needle vibrators working in any bay. A vibrating screed
consisting of a steel or timber section weighing not less than 15 kg. per metre with a tamping edge of
not less than 7 cm width and having a vibrator mounted thereon shall follow needle vibrators to
obtain full compaction. The face of the wooden tamping edge of the screed shall be lined with M.S.
Plate rigidly fixed by means of counter sunk screw. Where screed vibrators are used for compaction,
a standby unit shall always be maintained ready for use, should the other one go out of order. Where
electrically driven vibrators are employed, a standby diesel pneumatic unit shall be kept ready for
use in case of power failure. At the discretion of the Engineer-in-Charge, for compaction at edges
and joints, vibrators may be supplemented by hand tamping and rodding for securing satisfactory
results. Under no circumstances, honey combing of concrete at joints or elsewhere shall be permitted.
16. 37.8.3 When using screed vibrator for compaction it should not be dragged over the concrete.
During the initial passes it shall be lifted to the adjacent forward position in short steps, subsequently,
it shall be slowly slided over the surface with its axis slightly tilted away from the direction of sliding
and the operation repeated until a close, dense surface is obtained.
16.37.8.4 Concreting shall be carried out in one operation between the expansion joints and
construction joints without any break at the dummy joints.
16.37.8.5 Concrete shall be deposited on the base as near the joints as possible without touching
them. It shall then be shoveled against the sides, maintaining equal pressure and deposited approx.
50 mm higher than the depth of the joints, care being taken that it is worked well around the joints.
The concrete shall not be dumped from the bucket directly upon or against the joints.
16.37.8.6 Workmen shall not be allowed to walk on freshly laid concrete and proper cat walk shall be
provided with independent supports beyond concreting bays.
16.37.9 Finishing of Concrete

16.37.9.1 During compaction, any low or high spots shall be made up by adding or removing concrete.
After longitudinal floating has been completed but while concrete is still plastic, the slab surface shall
be tested for trueness with a 3 m straight edge. Any depressions or high spots showing departure
from the true surface shall be immediately rectified. High spots shall be cut down and refinished.
Depressions shall be enlarged to about 8-10 cm and filled up with fresh concrete, compacted and
finished.
16.37.9.2 The straight edge testing the refloating is to continue until the entire surface:
(a) is free from observable departure from the straight edge,
(b) conforms to the required levels and across section, and
(c) shall conform to the specified surface when the concrete has hardened.
16.37.9.3 The foregoing work is to be carried out while the concrete is still plastic and workable.
16.37.10 Belting
16.37.10.1 Just before concrete becomes non-plastic, the surface shall be belted with a two ply
canvas belt not less than 20 cm wide and at least 1 metre longer than the width of the slab. Hand
belts shall have suitable handles to permit controlled uniform manipulation. The belt shall be operated
with short strokes transversed to the centre line of the pavement and with rapid advance parallel to
the centre line.

16.37.11 Brooming
16.37.11.1 After belting and as soon as the surplus water, if any, has risen to the surface, the
pavement shall be given a broom finish with an approved steel or fiber broom not less than 45 cm
wide. The broom shall be pulled gently over the surface of the pavement from edge to edge. Adjacent
strokes shall be slightly overlapped. Brooming shall be perpendicular to the centre line of the pavement
and so executed that the corrugations formed shall be uniform in character and width and not more
than 1.5 mm deep.
16.37.11.2 Brooming shall be completed before the concrete reaches such a stage that the surface
is likely to be torn or unduly roughened by the operation. The broomed surface shall be free from
porous or rough spots, irregularities, depressions, and small pockets such as may be caused by
accidental disturbing of particles of coarse aggregates embodied near the surface. The brooming
shall be of uniform pattern all through.
16. 37.11.3 Edging : After belting/brooming has been completed but before the initial setting of
concrete, the edges of the slab shall be carefully finished with an edger of 6 mm radius, and the
pavement edges shall be left smooth and true to line.
16.37.12 Honey Combing

16.37.12.1 The side forms shall not be removed until 12 hours or such longer period as the Engineer-
in-Charge may decide after the laying of concrete.
16.37.12.2 As soon as the side forms are removed, any minor honey combed area shall be filled with
mortar composed of one part of cement and two parts of fine aggregate. Major honey combing areas
or segregated concrete or other defective work or areas damaged by removal of the forms or concrete
damaged by rain or due to any other reason whatsoever shall be considered as defective work and
shall be removed and replaced by the contractor at his own expense. The total area of honey combed
surface shall not exceed 4 per cent of the area of the slab side. However, no individual honeycomb
patch shall exceed 0.1 sqm. Engineer-in-Charge’s decision as to whether the concrete is defective
or not shall be final and binding.
16.37.13 Surface Accuracy

16. 37.13.1 After the concrete has sufficiently hardened after about 12 hours and not later than 24
hours, the surface shall be tested again for high spots. All high spots shall be marked and those
exceeding 3 mm shall be ground down immediately. Care shall be taken to see that the grinding does
not in any way damage the concrete surface.
16.37.13.2 The final surface finish is to be such that when tested with a profilograh/roughness
indicator/or a 3 metre long straight edge or an equivalent mechanical unevenness indicator placed
anywhere within the same or adjoining slab in any direction on the surface, there shall be no variation
greater than 3 mm.
16.37.13.3 If the surface irregularity exceeding 3 mm still remains despite grinding as per para
16.37.13.2 the concrete shall be removed to its full depth. The area of concrete to be removed shall
be complete slab between the nearest joints, where the defective slab is less than 4.5 metres from
the expansion joint, the whole area upto the expansion joint shall be removed to the full depth. The
concrete so removed shall not be reused in the work. Fresh concrete shall be laid in the manner
already de-scribed in above paras and shall again be subject to test for surface accuracy and other
quality control measures. Nothing extra shall be paid on this account.
16.37.13.4 Every slab shall bear an impression not exceeding 3 mm in depth comprising the number
allotted to the slab and the date on which it is laid. This impression shall be formed by the contractor
when the concrete is green so as to leave permanent mark on setting.

16.37.13.5 Initial Curing
16.37.13.5.1 Immediately after completion of the finishing operations, the surface of the pavement
shall be entirely covered with wetted burlap, cotton or jute mats. The mats used shall be of such
length (or width) that as laid they shall extend at least 45 cm beyond the edges of the slab. The mats
shall be placed so that the entire surface and both edges of the slab are completely covered. This
covering shall be placed as soon as, in the judgment of the Engineer- in-Charge the concrete has
set sufficiently to prevent damage to the surface prior to being placed, the mats shall be thoroughly
saturated with water and shall be placed with the wettest side down. The mats shall be so placed and
weighed down as to cause them to remain in intimate contact with the surface covered, and the
covering shall be maintained full wetted and in position for 24 hours after the concrete has been
placed or until the concrete is sufficiently hard to be walked on without suffering damage. Water shall
be gently sprayed so as to avoid damage to the fresh concrete. If it becomes necessary to remove a
mat for any reason, the concrete slab shall not be exposed for a period of more than half an hour.
16.37.13.5.2 Worn burlap or burlap with holes shall not be permitted. Burlap reclaimed from previous
use other than curing concrete shall be thoroughly washed prior to use for curing purposes. If burlap
is obtained in strips, shall be laid to overlap by at least 150 mm.
16.37.14 Burlap shall be placed from suitable bridges. Walking on freshly laid concrete to facilitate
placing burlap shall not be permitted.
16.37.15 Final Curing

16.37.15.1 Upon the removal of the burlaps, the slab shall be thoroughly wetted and then cured
as follows:-
All joints shall be filled with filler in order to prevent the edges of joints from getting damaged and
entry of clay materials into the joints during final curing. Exposed edges of the slab shall be banked
with a substantial berm of earth. Upon the slab shall then be laid a system of transverse and longitudinal
dykes of clay about 50 mm high immediately covered with a blanket of sandy soil free from stones to
prevent the drying up and cracking of clay. The rest of slab shall then be covered with sufficient
sandy soil so as to produce a blanket of earth not less than 40 mm deep after wetting. The earth
covering shall be thoroughly wetted while it is being placed on the surface and against the sides of
the slab and kept thoroughly saturated with water for 21 days and thoroughly wetted down during the
morning of the 22nd day and shall thereafter remain in place until the concrete has attained the
required strength and permission is given by the Engineer-in-Charge. Thereafter the covering shall
be removed and the pavement cleaned and swept. If the earth covering becomes displaced during
the curing period, it shall be replaced to the original depth and resaturated.
16.37.15.2 Contractor shall appoint chowkidars at his expense to prevent workmen, cattle, etc.,
straying on the pavement concrete.
16.37.15.3 Concrete shall not be subjected to any load or weight of any plant until at least 28 days
after laying.
16.37.16 Construction Joints

16.37.16.1 Construction joints shall be provided as shown in the drawing and also at places where
concreting is stopped due to unforeseen circumstances. The joints shall be straight and vertical
through the full thickness of the slab. While concrete in adjacent bay is still green, flats of suitable
size shall be drawn along the edge and a groove of size 10 mm × 25 mm deep shall be neatly formed
and finished. The edges of the groove shall be full nosed. After curing of concrete is complete, this

groove shall be thoroughly cleaned of all sand dust and shall be perfectly dried and filled with hot
poured sealing compound conforming to grade B of IS 1834. Before filling with sealing compound the
faces of concrete of the joint shall be coated with primer of approved brand to a depth of 25 mm at
the rate of 2.6 liters per 10 square meters. Bitumen emulsion shall not be used as primer.
16.37.17 Dummy Joints

16.37.17.1 The joints shall be 10 mm wide and shall extend vertically from the surface of the slab to
a depth equal to 1/3rd of the thickness of the slab but not less than 4 cm in any case. The joint may
be formed by depressing into the soft but compacted concrete a high tensile M.S. or other approved
Tee of flat bar of depth not less than required depth of the joint plus 25 mm. The bar used for forming
the groove shall be coated with soft soap or other suitable lubricant to facilitate its removal when the
steel Tee or flat is removed joints shall be neatly formed with proper tools and mortar/fine material
from the slab itself. No additional cement mortar (rich or otherwise) shall be used.
16.37.17.2 Cutting or sawing by a saw mounted on a movable frame and driven mechanically shall
also be permitted as a method for making the joint. In this case the width may be reduced to 6 mm.
any other method for making joints can be followed with the prior approval of the Engineer-in-Charge.
16.37.17.3 In all cases, except where cutting is done with saw, the joint edges shall be bullnosed.
Care should be taken to see that the edges of the grooves are not damaged.
16.37.17.4 The grooves shall be filled with hot poured sealing compound conforming to Grade B of
IS:1834. Prior to filling with sealing compound, the joints shall be cleaned by compressed air and
primed with Shalijet primer or equivalent at the rate specified in Para 16.37.16.1
16.37.17.5 All joints shall be sealed as soon as practicable after 28 days of casting of cc pavement.
Joints shall be sealed flush with the adjacent pavement surface in summer and 3-4 mm below finished
concrete surface in winter. The pavement shall be opened to traffic only after joint sealing over the
entire pavement. To prevent tackiness or pickup under traffic, the exposed surfaces of the sealing
compound shall be dusted with hydrated lime, if directed by Engineer-in-Charge, for which nothing
extra shall be paid to the contractor.
16.37.17.6 In case of sudden rain or storm, the work can be concluded at the dummy joints but these
will then be formed as construction joints.
16.37.17.7 Before sealing of joints, it may be ensured that the groove extends fully across the bay
between consecutive longitudinal joints, in the case of transverse joints and is continuous in the
case of longitudinal joints. Any concrete or other foreign matter must be removed from the groove.
16.37.18 Concreting during Rains

16.37.18.1 To prevent damage to freshly laid concrete during monsoon, or sudden rains, the contractor
shall provide an adequate supply of tarpaulins or other water proof covering material. Any concrete
damaged by rain shall be removed and replaced by the contractor at his own cost as directed by the
Engineer-in-Charge.
16.37.19 Quality Control

The following quality control tests shall be carried out at frequencies specified against each as in
Table 16.33.

TABLE 16.33
S.No Test Test Method Frequency Acceptance Criteria
1 2 3 4 5
(i) COARSE AGGREGATE
(a) Flakiness index IS 2386 (Pt.1) Before approval of the Not more than 15%
quarry and at every
subsequent change in the
source of supply and one
test per 100 cum of
aggregates
(b) Impact value IS 2386 (Pt.4) -do- Not more than 30%
(c) Los angles IS 2386 (Pt.4) -do- Not more than 40%
abrasion value.
(d) Deleterious IS 2386 (Pt.2) Before approval of the As per table 1 of IS 383
materials. quarry and at every
source of supply
(e) Moisture content. IS 2386 (Pt.3) Regularly as required -do-
subject to a min. one test
per day
(ii) FINE AGGREGATES
(a) Silt content. CPWD One test per 15 cum Not more than 8%
specifications
2019, Vol. I,
SH: CC
(b) Gradation of sand IS 2386 (Pt.1) -do- Fineness modulus
between 2.5 to 3.9
(c) Deleterious IS 2386 (Pt.2) Before approval of the As per table 1 of IS 383
materials. quarry and at every
source of supply
(d) Moisture content. IS 2386 (Pt.3) Regularly as required -do-
subject to a min. 2 test/day
(iii) MIXED AGGREGATES
(a) Grading IS 2386 (Pt. 1) 1 test per 15 cum As per para 16.37.1.5
(iv) Slump test of IS 1199 At least once in 50 batches Not more than 25 mm
concrete at each mixer or more
frequently if directed by the
Engineer-in-Charge
(v) Flexural strength IS 516 One test of sample As per para 16.37.3.5.
consisting of eight
specimen for every 30 cum
of concrete
(vi) Surface accuracy As prescribed Regularly As per para 16.37.13
16.37.20 Equipments
16.37.20.1 Equipments as per list at Appendix C shall be provided by the contractor in the field testing
laboratory. Nothing extra shall be paid to him on this account. Records as required shall be maintained
at site. All tests details in support of mix design shall be maintained as part of records of the contract
and shall be signed both by the contractor and the Engineer-in-Charge. The contractor shall provide
all labour, materials and equipment required for all tests to be carried out at his own cost.
16.37.20.2 The Engineer-in-Charge reserves the right to test any part of concrete laid regarding
quality soundness, compactness, thickness, strength and finish of the concrete, at any time before
the expiry of the “Defect liability period” not withstanding that necessary tests had been carried out
and found satisfactory at the time of execution.

16.37.20.3 All defective unsound sub-standard work and concrete of sub-standard strength and
quality etc. as established vide paras 16.37.3 shall be rejected and shall be replaced by the contractor
at his own expense in the manner as detailed in para 16.37.3. Where due to operational or any other
reason such replacement does not become possible (decision of Engineer-in-Charge in this respect
being final and binding on the contractor), the cost of removal and replacement of such rejected
work shall be recovered from the contractor whether such rejected work is subsequently replaced by
the Government or not.
16.37.21 Defects Liability Period

16.37.21.1 This period shall be reckoned in the case of this work as one year from the date of
completion of work and it shall be the liability of the contractor to repair, strengthen or reconstruct
any portion of the work which has shown damage or any defect, arising out of any bad workmanship
or defective material used in the work during this period. In the case of this rectification not being
commenced by the contractor within 7 days from the date of notice from the Engineer-in-Charge and
completed expeditiously the Engineer-in-Charge reserves the right to get the repair work executed
at the risk and cost of the contractor.
16.37.22.1 For the purpose of ascertaining the quantity of concrete in the pavement, thickness shall
be measured by means of a scale correct to the nearest 2 mm. The thickness of the concrete
pavement slabs shall be taken on either side of the pavement at each dummy joint at four corners of
the slab immediately after removal of the side forms. In case the average thickness of the slab
exceeds the specified thickness, payment shall be restricted to the specified thickness.
16.37.22.2 The dimensions of each slab of pavement shall be measured as follows to the nearest 5 mm.
(a) Length
(i) Between the end of a pavement to the centre line of the expansion joints.
(ii) Between the centre lines of consecutive expansion joints.
(b) Width
(i) Between the edge of a pavement and the centre line of the construction joints.
(ii) Between the centre lines of construction joints and expansion joints.
(iii) Between the centre lines of consecutive construction joints.
Note : The quantity of concrete in the pavement slab shall be worked out by multiplying the area of
the slab and its average thickness or specified thickness whichever is less. No deduction shall be
made for any joints in the concrete slab.
16.37.22.3 Measurements of concrete slabs shall be recorded jointly by the Engineer-in-Charge or

his authorised subordinate and the contractor or his authorised agent.
16.37.23 Rate
The rate of the item for concrete in pavement shall include the cost of all materials and labour
including charges for machinery tools & plants required in all the operations described above. The
rate also includes all cost of setting up the laboratory at site and carrying out the quality control
measures/tests enumerated above by the contractor at his own cost in the presence of Engineer-in-
Charge or his authorized representative and submission of test results on completion of tests to the
Engineer-in-Charge thereof.

16.38 HARD CRETE
Hard crete of approved quality and brand to be used. It shall be mixed in ratio and method as
recommended by manufacturer and approved by Engineer-in-charge in cement concrete for laying
in paramount. Quantity shall be measured in litre used in cement concrete. Hardcrete to be brought
in sealed container and proper record of quantity be maintained. Empty containers of hardcrete
shall not be removed from site with but prior permission of Engineer-in-Charge.
16.39 EXPANSION JOINT
16.39.0 Materials
Premoulded Joint Filler in Expansion Joint : It shall conform to IS 1838 (Pt. I). The thickness shall
be 25 mm with tolerance 1.5 mm. and shall be of the maximum available standard length not less
than one lane width. The filler board shall be positioned vertically with the prefabricated joint assemblies
along the line of the joint within tolerance of + 10 mm from the intended line of the joint. The depth of
board shall be 25 mm less than thickness of slab within a tolerance of ± 3mm so that the top of the
board shall be below the surface or will not impead the passage of the finishing straight edge or
oscillating beam of the paving machine.
Bitumine Hot Sealing Compound : The joint sealing compound shall be fuel and heat resistant type
complying to grade B of IS 1834. It shall be capable of adhering to the concrete without cracking,
spalling and disintegration.
16.40 CONSTRUCTION PROCEDURE

16.40.1 Expansion joints shall be provided as shown in the drawing and as per directions of Engineer-
in-Charge. All joints shall be constructed true to line with their faces perpendicular to the surface of
the pavement. The joint shall be 20 mm wide. The depth of the non-extruding filler pad shall be 25
mm less than the depth of the concrete slab.
16.40.2 Before the provision of expansion joint, the face of the already laid concrete slab shall be
painted with primer at the rate of 2.6 liters per 10 square metres. The expansion pad shall be properly
cut to shape and shall then be placed in position abutting the painted face of the already laid concrete
slab. The adjacent slab shall then be concreted. The face of the pad against which the new concrete
slab is to be laid shall also be painted with primer before laying the concrete, while concreting a neat
groove of size 20 mm x 25 mm as per drawing shall be formed on top of the pad taking care that the
edges are absolutely straight and that the groove so made does not get filled with any material like
concrete, mortar and other rubbish.
16.40.3 Before the curing process is started, the top of expansion joint shall be filled with bitumen
sand mixture in order to ensure that no foreign material used in curing enters into the joint. This
filling shall be removed before filling the joints with sealing compound.
16.40.3.1 For sealing the joints following operations shall be carried out :—
(a) The joints are cleared of any foreign matter to the full depth upto the top of expansion pad
with steel spatula.
(b) The joints are blown with compressed air.
(c) Cleaning is done with Kerosene oil.
(d) Priming is done with spray gun @ 2.6 liters per 10 sqm of the surface to be primed.
(e) The primer is allowed to dry completely before pouring the sealing compound.
(f) The sealing compound grade ‘A’ is heated to the required temperature ranging between
155 deg. C to 165 deg. C or to the temperature range specified by the manufacturer. Over

heating shall be avoided. Pouring shall be done from vessel with spout in such a manner
that the material will not get spilled on the exposed surface of the concrete, any excess filler
on the surface of the pavement shall be removed immediately and the pavement surface
cleaned.
(g) The filling shall be worked into the joints with hot flats to ensure escape of trapped air.
(h) The filling is then ironed with hot iron. It is recommended that while in summer the joints
may be sealed flush with the adjacent pavement surface, in winter the sealing compound
may be filled to a depth 3-4 mm below the surface.
(i) The edges of the joints are then cut and trimmed to ensure neat and straight line finish.
(j) To prevent tackiness or pick up under traffic, the exposed surfaces of the sealing compound
shall be dusted with hydrated lime, if directed by Engineer-in-Charge (Nothing extra shall
be paid for the same).
16.40.3.2 Measurements : The measurement of the specified depth of joint shall be recorded in
metres correct to two places of decimals.
16.40.4 Rate
Rate for the item shall include the cost of all materials, plant, machinery and labour involved in all
operations described above, including all cartages and lifts.
16.41 PAINTING ROAD/ RUNWAYS MARKINGS
16.41.1 Materials
16.41.1.1 Special Road marking paint of approved brand and manufacture shall be used. The paint
shall conform to IS 164. Ready mixed paint as received from the manufacturer shall be used without
adding any admixture.
16.41.1.2 During work, if the consistency of the paint gets thick and thinning becomes necessary it
shall be done by use of thinner of the approved brand of paint recommended by the manufacturer
and with the approval of the Engineer-in-Charge.
16.41.1.3 The paint shall be brought to the site of work by the contractor in original sealed containers.
The material shall be brought in one lot in adequate quantity to suffice for the entire work. The
material shall be kept in the joint custody of the contractor and the Engineer-in-Charge. The empty
container shall not be removed from the site of work, till the work has been completed and permission
obtained from the Engineer-in-Charge.

The surface shall be thoroughly cleaned and free from dust. All the dirt, scales, oil and grease
shall be thoroughly removed before painting is started. The prepared surface shall be inspected
and approved by the Engineer-in-Charge before painting is commenced.
16.41.3 Application
16.41.3.1 Before pouring into smaller containers for use, the paint shall be stirred thoroughly in its
original container. The paint shall be continuously stirred in the smaller container while applying to
runway surface so that its consistency is kept uniform.
16.41.3.2 The painting shall be applied evenly and smoothly by means of crossing and laying off. The
crossing and laying off consists of covering the area over with paint, brushing the surface hard for the
first time over and then brushing alternatively in opposite direction, two or three times and then finally
brushing lightly in a direction at right angle to the same. In this process, no brush marks shall be left
after the laying off is finished. The full process of crossing and laying off will constitute one coat.

16.41.3.3 Each coat shall be allowed to dry out thoroughly before the next coat is applied.
16.41.3.4 Earlier applied coat shall be cleaned off dust before the next coat is laid.
16.41.3.5 No left over paint shall be put back into the stock tins. When not in use, the containers shall be kept
properly closed.
16.41.3.6 No hair marks from the brush or clogging of paint puddles shall be left on the work.
16.41.3.7 The surface shall ordinarily not be painted until it has dried up completely. Trial patches of paint
shall be laid at intervals to check if drying is satisfactory.
16.41.3.8 The runway marking shall be done in accordance with the drawing unless otherwise instructed by
16.41.4 Brushes and Containers

16.41.4.1 After work, the brushes shall be completely cleaned of paint by rinsing with turpentine. A brush in
which paint has dried up is spoiled and shall on no account be reused for painting work. On no account
kerosene oil shall be used for washing the brush.
16.41.4.2 When the paint has been used, the containers shall be washed with turpentine and wiped dry with
soft clean cloth so that they are clean, and can be used again.
16.41.5 Measurement
16.41.5.1 Length and breadth shall be measured correct to a cm. Area shall be worked out in square metre,
correct to two places of a decimal.
16.41.6 Rate
16.41.6.1 Rate shall include cost of all materials, tools and labour involved in all the operations described
above including all cartages and lifts.
16.42 PAINTING ROAD SURFACE (WITH READY MIXED ROAD MARKING PAINT)
Specifications of item no. 16.41 to be followed except that road surface to be painted with ready mixed
road marking paint of approved brand instead of paint of superior make.
16.43 LIME FLY ASH STABILISED SOIL SUB BASE

16.43.1 The thickness of lime flyash soil layer for use as sub base should be designed in accordance with IRC
37. The minimum thickness shall not be less than 15 cm.
16.43.2 Soil
Granular soils free from high concentration of organic matter or deleterious salts and sand with fine silts
produce better mixes than fine grained soil with high clay content. Clay, silts and low plastic clays with
plasticity index between 5 and 20 and liquid limit less than 25 are however, suitable the minimum proportion
of particles smaller than 425 micron should be between 15 and 25 percent by dry weight of the soil lime flyash
mixture. Selection of material and their gradation should be such as would be conducive to compaction to
high density.
16.43.3 Lime
Should be commercial dry lime slaked at site or pre-slaked and delivered in airtight sacks. Suitable
approved lime should have purity (Cao content ) of not less than 50 percent. Only hydrated high calcium and
mono hydration dolomitic limes are to be used. Quick lime is not recommended for use. Where in exceptional
circumstances, when with 50% purity is not available, the deficiency can be compensated by using larger
proportion of lime.

16.43.4 Flyash
Shall conform to IS 3812. If it is partially set due to long storage, it should be pulverised and dry
sieved before mixing, to conform to following grading.
Sieve Size mm) Percent passing

12.5 100
9.5 95 (min)
2.0 75 (min)
Flyash should be fine enough to have a specific surface are of 3200 sq.cm/gm or 320 sqm/kg. It
should be ensured before its use, that flyash possesses lime relativity of not less than 35 kg/sq.cm.
Flyash should be stored in covered area safe from moisture.
16.43.5 Mix Proportioning

The mix proportion shall be determined in conformity with IRC -88 through laboratory tests for
meeting the strength requirements. A typical mix proportion of soil lime, flyash is given below :
Soil 85 parts by weight
Lime 3 parts by weight
(based on 80% purity of lime)
Flyash 12 parts by weight
16.43.6 Tolerance
Limits of tolerance for various materials in percentage by weight shall be as follows
Lime ± 0.3
Flyash ± 1.5
Soil ± 2.0
16.43.7 Surface Irregularities

The finish surface should be checked for line, level and grade and surface finish. The maximum
permissible undulation in longitudinal profile shall not exceed 15 mm when checked with 3 metre
straight edge and in cross profile the variation from specified profile shall not exceed 12 mm.
The quantity of water shall be as per the O.M.C. requirements determined on soil lime flyash
mixture by proctor density method.
16.43.8 Construction Operation
Mixing shall preferably be done by mechanical plant either of the single pass or multiple pass
type, where such plant is not available, manual method may be adopted with rigorous control over
quality of construction. In the manual method, the soil shall be pulverised by means of crowbars, pick
axes, bullock drawn ploughs etc. and deposited on the road bed in stacks of suitable size, about 30
cm in height. Water in requisite quantities shall be sprinkled on the soil for aiding pulverisation. The
degree of pulverisation shall be as given in Table 16.34.
TABLE 16.34
Sieve Designation % by weight passing the sieve.
25 mm 100
4.75 mm 60

On the pulverised soil stacks, lime and flyash in a thoroughly mixed form and in the requisite
quantities shall be spread uniformly and mixed by cutting with spade till the whole mass is uniform.
The mixed soil shall then be spread over the prepared sub-grade to the required thickness and
rolled. Before rolling, the moisture content shall be adjusted to be within + 1% and -2% of the O.M.C.
16.43.9 Rolling
Rolling shall be done with a 8-10 tonne roller. Rolling is continued till the required density (100%
of Lab. Proctor density as per IS 2720 Pt.VII) and a smooth surface obtained without leaving any
roller marks on the surface. During rolling surface should be checked for grade and camber and
irregularities corrected.
16.43.10 Curing
The compacted surface shall be cured for a minimum period of 7 days before the next layer is
placed. Curing is done by sprinkling water over the surface five or six times a day. The surface shall
not be allowed to dry during the curing period. Curing by ponding shall not be adopted.
The length and breadth shall be taken to the nearest centimeter and the thickness to the nearest
half centimeter. The consolidated cubical contents shall be calculated in cubic metres, correct to two
places of decimals.
16.43.12 Rate
above.
16.44 PRECAST LIME FLY ASH CONCRETE BLOCKS

16.44.1 Material
Precast lime fly ash concrete blocks 1:2:3:6 (1 lime : 2 fly ash : 3 coarse sand : 6 graded
stone aggregate 20 mm nominal size) finished with 10 mm, thick cement mortar 1:3 (1 cement :
3 coarse sand).
16.44.1.1 Laying : Prepare the sub grade with a hand rammer and laying 10 mm thick levelling
course of fine sand (Jamuna sand). Laying the precast lime flyash concrete blocks as specified over
base as described above and filling the joints with fine sand.
16.44.2 Measurement
Length breadth & thickness of block shall be measured of finished work. Correct to a cm. and
calculated in cubic metre. Correct to two decimal places.
16.44.3 Rate
The rate shall include the cost of material & labour involved in all operations described above.
16.45 CONCERTINA COIL FENCING

16.45.1 Material : Angle iron post & strut shall be as specified in 16.18.
Concertina coil fencing shall be dia 610 mm (having 15 nos round per 6 mtre. length), spring core
(2.5 mm thick) wire of high tensile strength of 165 kg./sq.mm with tape (0.52 mm thick) and weight
43.478 gm/metre.
16.45.2 Spacing of Posts & Struts: The spacing of posts shall be 2.4 m or 3.00 m apart centre to
centre, unless otherwise specified or as per Engineer-in -Charge to suit the dimension of the area to
be fenced. Every 15th last but one end posts and corner posts shall be strutted on both sides and
end posts on one side only.

16.45.3 Fixing of Posts and Struts : As specified in the 16.17.3.
16.45.4 Fixing Concertina coil fencing shall be fixed on angle iron shaped with 9 horizontal reinforced barbed
tape (RBT) stud tied with GI staples and GI clips to retain horizontal including necessary bolts or GI barbed
wire tied to angle iron all complete as per directions of Engineer-in-Charge with reinforced barbed tape.
The length of fencing shall be measured correct to a cm. for finished work.
16.45.6 Rate
The rate shall include the cost of labour and materials involved in all the operation described above but
excluding the cost of M.S. angle and excavation and concrete in foundation for which separate payment shall
be made under respective items.
16.46 DENSE GRADED BITUMINOUS MACADAM (DBM)

16.46.1 Scope
Dense Bituminous Macadam (DBM) for use mainly but not exclusively, for in base/binder and profile
corrective courses. DBM is also used as road base material. This work shall consist of construction in a
single or multiple layers of DBM on a previously prepared base or sub-base. The thickness of a single layer
shall be 50 mm to 100 mm.
16.46.2 Material
16.46.2.1 Bitumen : The bitumen shall be viscosity grade paving bitumen complying with the Indian Standard
Specification IS:73, or as otherwise specified in the item. The type and grade of bitumen to be used shall be
specified in the item of Contract. Where modified bitumen is specified, it shall conform to the requirements of
IRC:SP:53 and IS:15462.
Section criteria for viscosity grade bitumen, based on highest and lowest daily mean temperatures at a
particular site are given in Table 16.40A.
Selection criteria for modified bitumen shall be in accordance with IRC:SP53.
16.46.2.2 Coarse Aggregates : The coarse aggregates shall consist of crushed rock, crushed gravel or other
hard material retained on the 2.36 mm IS Sieve. They shall be clean, hard, durable, or cubical shape, free from
dust and soft or friable matter, organic or other deleterious substance. Before approval of the source, the
aggregates shall be tested for stripping. The aggregates shall satisfy the physical requirements specified in
Table 16.35, for dense bituminous macadam.
Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of the crushed
material retained on the 4.75 mm IS Sieve shall have at least two fractured faces.
16.46.2.3 Fine Aggregates : Fine aggregates shall consist of crushed or naturally occurring mineral material,
or a combination of the two, passing the 2.36 mm IS Sieve and retained on the 75 micron sieve. These shall
be clean, hard, durable, dry and free from dust and soft or friable matter, organic or other deleterious matter.
Natural sand shall not be allowed in binder courses. However, natural sand upto 50 percent of the fine aggregate
may be allowed in base courses.
The fine aggregate shall have a sand equivalent value of not less than 50 when tested in accordance with
the requirements of IS 2720 (Part 37).
The plasticity index of the fraction passing the 0.425 mm IS Sieve shall not exceed 4, when tested in
accordance with IS 2720 (Part 5).

TABLE 16.35
Physical Requirements for Coarse Aggregate for Dense Bituminous Macadam
Property Test Specification Method of Test
Max 5% passing 0.075mm IS:2386 Part 1
Cleanliness (dust) Grain size anlysis7 sieve.
Combined Flakiness and IS:2386 Part 1
Particle shape Elongation Indices* Max 35%
Strength Los Angeles Abrasion Value IS:2386 Part 4
or Max 35%
Aggregate Impact Value Max 27%
Durability Soundness either: IS:2386 Part 5
Sodium Sulphate Max 12%
or Max 18%
Magnesium Sulphate
Water Absorption Water Absorption Max 2% IS:2386 Part 3
Coating and stripping of Bitumen Minimum retained coating IS:6241
Stripping aggregate Mix 95%
Water sensitivity Retained Tensile Strength** Min 80% AASHTO 283
* To determine this combined proportion, the flaky stone from a representative sample should first
be separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample.
Only the elongated particles be separated out from the remaining (non-flaky) stone metal.
Elongation index is weight of elongated particles divided by total non-flaky particles. The values
of flakiness index and elongation index so found are added up.
** If the minimum retained tensile test strength falls below 80 percent, use of anti stripping agent
is recommended to meet the requirement.
16.46.2.4 Filler : Filler shall consist of finely divided mineral matter such as rock dust, hydrated
lime or cement approved by the Engineer-in-Charge. The filler shall be graded within the limits
indicated in Table 16.36.
TABLE 16.36
Grading Requirements for Mineral Filler
Is Sieve (mm) Cumulative per cent passing by weight of total aggregate

0.6 100
0.3 95-100
0.075 85-100
The filler shall be free from organic impurities and have a plasticity index not greater than
4. The Plasticity Index requirements shall not apply if filler is cement or lime. Where the
aggregates fail to meet the requirements of the water sensitivity test in Table 16.35, then 2
percent by total weight of aggregate, of hydrated lime shall be used and percentage of fine
aggregate reduced accordingly.

16.46.2.5 Aggregate Grading and Binder Content : When tested in accordance with IS 2386 Part
1 (wet sieving method), the combined grading of the coarse and fine aggregates and added filler for
the particular mixture shall fall within the limits shown in Table 16.37 for dense bituminous macadam.
To avoid gap grading the combined aggregate grading shall not vary from the low limit on one sieve
to the high limit on the adjacent sieve.
TABLE 16.37
Composition of Dense Graded Bituminous Macadam Pavement Layers
Mix Designation Grading 2
Nominal aggregate size* 26.5 mm
Layer Thickness 50-75 mm
IS Sieve1 (mm) Cumulative % by weight of total aggregate passing
37.5 100
26.5 90-100
19 71-95
13.2 56-80
4.75 38-54
2.36 28-42
0.3 7-21
0.075 2-8
Bitumen content percent by mass of Min 4.5** or as specified in the item
total mix (Marshal method)
Bitumen grade As specified in item or directed otherwise.
* The nominal maximum particle size is the largest specified sieve size upon which any of the aggregate
is retained.
** Corresponds to specific gravity of aggregates being 2.7. In case aggregate have specific gravity
more than 2.7, the minimum bitumen content can be reduced proportionately. Further the region
where highest daily mean air temperature is 30º C or lower and lowest daily air temperature is – 10 º
C or lower, the bitumen content may be increased by 0.5 percent.
16.46.2.6 Bitumen content indicated in Table 16.37 is the minimum quantity. The quantity shall be
determined in accordance with the Mix Design. Para 16.46.3
16.46.3 Mix Design

The bitumen content required shall be determined following the Marshall mix design procedure
contained in Asphalt Institute Manual MS-2.
The Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.
16.46.3.1 Requirement for the Mix: The mix shall meet the requirements as given in Table 16.38.

TABLE 16.38
Requirements for Dense Bituminous Macadam
Viscosity Grade Modified bitumen

Properties Test Method
Paving Bitumen Hot climate Cold climate
Compaction level 75 blows on each face of the specimen
Minimum stability
9.0 12.0 10.0 AASHTO T245
(kN at 60º C)
Marshall flow
2–4 2.5 - 4 3.5 - 5 AASHTO T245
(mm)
Marshall Quotient
MS-2 and ASTM
Stability 2–5 2.5 - 5
D2041
Flow
% air voids 3–5
% Voids Filed with
65 – 75
Bitumen (VFB)
Coating of
95% Min. IS:6241
aggregate particle
Tensile Strength
80% Min. AASHTO T283
ratio
% Voids in Mineral
Minimum percent voids in mineral aggregate (VMA) are set out in Table 16.40
Aggregate (VMA)
TABLE 16.39
Minimum Percent Voids in Mineral Aggregate (VMA)
1
Nominal Maximum Particle size (mm) Minimum VMA, Percent Related to Design
Percentage Air voids
3.0 4.0 5.0

26.5 11.0 12.0 13.0
37.5 10.0 11.0 12.0
Note: Interpolate minimum voids in the mineral aggregate (VMA) for designed percentage air voids
values between those listed.
16.46.3.2 Binder Content : The binder content shall be optimized to achieve the requirements of
the mix set out in Table 16.38. The binder content shall be selected to obtain 4 percent air voids in
the mix design. The Marshall method for determining the optimum binder content shall be adopted as
described in the Asphalt Institute Manual MS-2.
Where maximum size of the aggregate is more than 26.5 mm, the modified Marshall method using
150 mm diameter specimen described in MS-2 and ASTM D 5581 shall be used. This method requires
modified equipment and procedures. When the modified Marshall test is used, the specified equipment
and procedures. When the modified Marshall test in used, the specified minimum stability values in
Table 16.39 as above shall be multiplied by 2.25 and the minimum flow shall be 3 mm.
16.46.3.3 Job Mix Formula : The contractor shall inform the Engineer-in-Charge in writing, at least 21
days before the start of the work, of the job mix formula proposed for use in the works, and shall give
the details of Source and location of all materials, their sizes, grading, binder type and percentage by
weight of total mix, Coarse aggregate / Fine aggregate / Mineral filler as percentage by weight of total
aggregate including mineral filler and Mixing temperature and compacting temperature and test results.

While establishing the ob mix formula, the Contractor shall ensure that it is based on a correct
and truly representative sample of the materials that will actually be used in the work and that the mix
and its different ingredients satisfy the physical and strength requirements of these Specifications.
Approval of the job mix formula shall be based on independent testing by the Engineer-in-Charge
for which samples of all ingredients of the mix shall be furnished by the Contractor as required by the
Engineer-in-Charge.
Job mix formula shall be revised if there is a change in source of material and be got approved by
Engineer-in-Charge.
16.46.3.4 Plant Trials – Permissible Variation in Job Mix Formula: Once the laboratory job mix
formula is approved, the Contractor shall carry out plant trials at the mixer to establish that the plant
can be set up to produce a uniform mix conforming to the approved job mix formula. The permissible
variations of the individual percentages of the various ingredients in the actual mix from the job mix
formula to be used shall be within the limits as specified in Table 16.40.
TABLE 16.40
Permissible Variations in the Actual Mix from the Job Mix Formula
Description Permissible Variation
Base/Binder Course Wearing Course
Aggregate passing 19 mm sieve or larger ± 8% ± 7%
Aggregate passing 13.2 mm, 9.5 mm ± 7% ± 6%
Aggregate passing 4.75 mm ± 6% ± 5%
Aggregate passing 2.36 mm, 1.18 mm, ± 5% ± 4%
0.6 mm
Aggregate passing 0.3 mm, 0.15 mm ± 4% ± 3%
Aggregate passing 0.075 mm ± 2% ± 1.5%
Binder content ± 0.3% ± 0.3%
Mixing temperature ± 10°C ± 10°C
16.46.3.5 Laying Trials : Once the plant trials have been successfully completed and approved, the
Contractor shall carry out laying trials, to demonstrate that the proposed mix can be successfully laid
and compacted.

16.46.4.1 Preparation of Base : The base on which DBM is to be laid shall be prepared, shaped
and compacted to the required profile as appropriate or as directed by the Engineer-in-charge. The
surface shall be thoroughly swept clean by a mechanical broom, and the dust removed by compressed
air, in locations where mechanical broom cannot get access, other approved methods shall be used
as directed by the Engineer-in-charge.
16.46.4.2 Tack Coat : Where the material on which the dense bituminous macadam is to be laid is
either bitumen bound layer or primed granular layer, tack coat shall be applied as specified, in
accordance with the provisions of para 16.29, or as directed by the Engineer-in-Charge.
16.46.4.3 Mixing and Transportation of the Mixture : The provisions are as specified in the para
16.47.3.3 shall apply. Table 16.41A gives the mixing laying and rolling temperature for dense mixes
using viscosity grade bitumen. In case of modified bitumen, the temperature of mixing and compaction
shall be higher than the mix with viscosity grade bitumen. The exact temperature depends upon the
type and amount of modifier used and shall be adopted as per the recommendations of the
manufacturer. In order to have uniform quality, the plant shall be calibrated from time to time.

16.46.4.4 Spreading : The provisions are as specified in the para 16.47.3.5 shall apply. The paver
finisher shall be fitted with electronic sensor device.
16.46.4.5 Rolling / Compaction & Joints : The provisions are as specified in the para 16.47.3.6
and 16.47.3.7 shall apply, as modified by the approved laying trials. The compaction process shall
be carried out by the same plant, and using the same method, as approved in the laying trials, which
may be varied only with the express approval of the Engineer-in-charge in writing.
16.46.5 Opening to Traffic : The newly laid surface shall not be open to traffic for at least 24 hours
after laying the completion of compaction, without the approval of the Engineer-in-Charge in writing,
on the surface until the DBM layer has cooled to the ambient temperature.
16.46.6 Surface Finish and Quality Control of Work : The surface finish of the completed
construction shall conform to the requirements of section 900 of MORTH Specifications. For control
of the quality of materials supplied and the works carried out the relevant provisions of Section 900
of MORTH Specifications.
16.46.7 Arrangement for Traffic : During the period of construction, arrangements for traffic shall
be made in accordance with the provisions of specification and as per direction of the Engineer-in-
charge.
16.46.8 Measurement
Dense Bituminous Macadam shall be measured as finished work in cubic meters, correct to two
places of decimal.
16.46.9 Rate
The rate includes the cost of all material, labour, machineries and equipments in all the operations
described above.
16.47 BITUMINOUS MACADAM

16.47.1 Scope
This work shall consist of construction in a single course having 60 mm to 100 mm thickness or in
multiple courses of compacted crushed aggregates premixed with a bituminous binder on a previously
prepared base to the requirements of these Specifications. Since the bituminous macadam is an
open-graded mix, there is a potential that it may trap water or moisture vapour within the pavement
system. Therefore, adjacent layer (shoulders) should have proper drainage quality to prevent
moisture-induced damage to the BM.
16.47.2 Material
16.47.2.1 Bitumen : The bitumen shall be viscosity grade paving bitumen complying with the
Indian Standard Specification IS:73, or as otherwise specified in the item. The type and grade of
bitumen to be used shall be specified in the Contract. The type and grade of bitumen to be used
would depend upon the climatic conditions and the traffic. Guidelines for selection of bitumen are
given in Table 16.40A.
Table 16.40A
Selection Criteria For Viscosity-Graded (VG) Paving Bitumen Based
On Climatic Conditions
Lowest Daily Mean Air Highest Daily Mean Air Temperature, ºC
Temperature ºC Less than 20ºC 20 to 30ºC More than 30ºC
More than -10ºC VG-10 VG-20 VG-30
-10ºC or lower VG-10 VG-10 VG-20

16.47.2.2 Coarse Aggregates - same as 16.46.2.2 excepting strength which shall be max 40% for
Los Angeles Abrasion Value and Aggregate Impact Value of max 30%.
16.47.2.3 Fine Aggregates : Same as 16.46.2.3.
16.47.2.4 Proportioning of Material:

The combined aggregate grading shall not vary from the lower limit on one sieve to the higher limit
on the adjacent sieve to avoid gap grading. The aggregate may be proportioned and blended to
produce a uniform mix complying with the requirements in Table 16.41. The bitumen content and
appropriate thickness are as per Table 16.41.
TABLE 16.41
Composite of Bituminous Macadam
Mix Designation Grading 2
Nominal maximum aggregate size* 19 mm
Layer Thickness 50-75 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
26.5 100
19 90-100
13.2 56-88
4.75 16-36
2.36 4-19
0.3 2-10
0.075 0-8
Bitumen content** percent by mass to
total mix 3.4** or as specified in the item
Bitumen grade As specified in item or directed otherwise
* Nominal maximum aggregate size is the largest specified sieve size upon which any of the
aggregate material is retained.
** Corresponds to specific gravity of the Aggregate being 2.7. In case aggregates have specific
gravity more than 2.7, bitumen content can be reduced proportionately. Further, for regions
where highest daily mean air temperature is 30º C or lower and lowest daily mean air
temperature is – 10º C or lower, the bitumen content may be increased by 0.5 percent.
16.47.2.5 Aggregate Grading and Binder Content : When tested in accordance with IS 2386 Part
1 (wet sieving method), the combined grading of the coarse and fine aggregates and added filler for
the particular mixture shall fall within the limits shown in Table 16.41 for bituminous macadam.
16.47.3 Construction Operation

16.47.3.1 Preparation of the Base: The base on which bituminous macadam is to be laid shall be
prepared, shaped and compacted to the required profile as appropriate, and a prime coat, shall be
applied as specified, in accordance with the provisions or as directed by the Engineer-in-charge.
The surface shall be thoroughly swept clean by a mechanical broom, and the dust removed by
compressed air, in locations where mechanical broom cannot get access, other approved methods
shall be used as directed by the Engineer-in-charge.
16.47.3.2 Tack Coat : Where the material on which the bituminous macadam is to be placed is
bitumen bound surface, a tack coat shall be applied as specified, in accordance with Para 16.29, or
as directed by the Engineer-in-Charge.

16.47.3.3 Mixing and Transportation of the Mixture : Pre-mixed bituminous materials, shall be prepared in
a hot mix plant of adequate capacity and capable of yielding a mix of proper and uniform quality with thoroughly
coated aggregates. Appropriate mixing temperatures are given in Table 16.41A of these Specifications; the
difference in temperature between the binder and aggregate should at no time exceed 14ºC. In order to ensure
uniform quality of the mix and better coating of aggregates, the hot mix plant shall be calibrated from time to
time. The essential features of the hot mix plants are given in Annex. A of IRC:27.
If a continuous type mixing plant is used, the Contractor must demonstrate by laboratory analysis that
the cold feed combined grading is within the grading limits specified for that bituminous bound material. In the
case of a designed job mix, the bitumen and filler content shall be derived using this combined grading.
Bituminous materials shall be transported in clean insulated vehicles, and unless otherwise agreed by
the Engineer, shall be covered while in transit or awaiting tipping. Subject to the approval of the Engineer, a
thin coating of diesel or lubricating oil may be applied to the interior of the vehicle to prevent sticking and to
facilitate discharge of the material.
TABLE 16.41A
Mixing, Laying and Rolling Temperatures for Bituminous Mixes (Degree Celsius)
Bitumen Bitumen Aggregate Mixed Laying *Rolling
Viscosity Temperature Temperature Material Temperature Temperature
Grade Temperature
VG-40 160-170 160-175 160-170 150 Min. 100 Min.
VG-30 150-165 150-170 150-165 140 Min. 90 Min.
VG-20 145-165 145-170 145-165 135 Min. 85 Min.
VG-10 140-160 140-165 140-160 130 Min. 80 Min.
* Rolling must be completed before the mat cools to these minimum temperatures.
16.47.3.4 Cleaning of Surface : The surface on which the bituminous work is to be laid shall be cleaned of
all loose and extraneous matter by means of a mechanical broom and air jet. or any other approved equipment/
method as specified in the contract. The use of a high pressure air jet from a compressor to remove dust or
loose matter shall be available full time on the site, unless otherwise specified in the Contract.
16.47.3.5 Spreading : Prior to spreading the mix, the base shall be prepared by carrying out the required
operation. Except in areas where a mechanical paver cannot get access, bituminous materials shall be
spread, leveled and tamped by an approved self-propelled paving machine equipped with an electronic sensing
device. The essential features of the paver finisher shall conform to Annex A of IRC:27. As soon as possible
after arrival at site, the materials shall be supplied continuously to the paver and laid without delay.
The rate of delivery of material to the paver shall be regulated to enable the paver to operate
continuously. The travel rate of the paver, and its method of operations, shall be adjusted to ensure
an even and uniform flow of bituminous material across the screed, free from dragging, tearing and
segregation of the material. In areas with restricted space where a mechanical paver cannot be
used, the material shall be spread, raked and leveled with suitable hand tools by experienced staff,
and compacted to the satisfaction of the Engineer-in-charge.
The minimum thickness of material laid in each paver pass shall be in accordance with the
minimum values given in the relevant parts of these Specifications. When laying binder course or
wearing course approaching an expansion joint of a structure, machine laying shall stop 300 mm
short of the joint. The remainder of the pavement up to the joint, and the corresponding area beyond
it, shall be laid by hand, and the joint or joint cavity shall be kept clear of surfacing material.
Bituminous material, with a temperature greater than 145ºC, shall not be laid or deposited on
bridge deck waterproofing systems, unless precautions against heat damage have been approved
by the Engineer-in-charge.

16.47.3.6 Rolling / Compaction : Bituminous materials shall be laid and compacted in layers which enable
the specified thickness, surface level, regularity requirements and compaction to be achieved.
Compaction of bituminous materials shall commence as soon as possible after laying. Compaction shall
be substantially completed before the temperature falls below the minimum rolling temperatures stated in the
relevant part of these Specifications. Rolling of the longitudinal joints shall be done immediately behind the
paving operation. After this, rolling shall commence at the edges and progress towards the center longitudinally
except that on super elevated and unidirectionally cambered portions, it shall progress from the lower to the
upper edge parallel to the center line of the pavement. Rolling shall continue until all roller marks have been
removed from the surface. All deficiencies in the surface after laying shall be made good by the attendants
behind the paver, before initial rolling is commenced. The initial or breakdown rolling shall be done with 8 – 10
tonnes dead weight smooth-wheeled rollers. The intermediate rolling shall be done with 8 – 10 tonnes dead
weight or vibratory roller or with a pneumatic tyred roller of 12 to 15 tonnes weight having nine wheels, with a
tyre pressure of at least 5.6 kg/sqcm or 0.56 MPa. The finish rolling shall be done with 6 to 8 tonnes smooth
wheeled tandem rollers. Rolling shall be continued until the specified density is achieved, or where no density
is specified, until there is no further movement under the roller.
Where compaction is to be determined by density of cores the requirements to prove the performance of
rollers shall apply in order to demonstrate that the specified density can be achieved. In such cases the
Contractor shall nominate the plant, and the method by which he intends to achieve the specified level of
compaction and finish at temperatures above the minimum specified rolling temperature. Laying trials shall
then demonstrate the acceptability of the plant and method used.
Bituminous materials shall be rolled in a longitudinal direction, with the driven rolls nearest the paver. The
roller shall first compact material adjacent to joints and then work from the lower to the upper side of the layer,
overlapping on successive passes by at least one-third of the width of the rear roll or, in the case of a
pneumatic-tyred roller, at least the nominal width of 300 mm.
In portions with super elevated and unidirectional camber, after the edge has been rolled, the roller shall
progress from the lower to the upper edge.
Rollers should move at a speed of not more than 5 km per hour. The roller shall not be permitted to stand on
pavement which has not been fully compacted, and necessary precautions shall be taken to prevent dropping of
oil, grease, petrol or other foreign matter on the pavement either when the rollers are operating or standing. The
wheels of rollers shall be kept moist with water, and the spray system provided with the machine shall be in good
working order, to prevent the mixture from adhering to the wheels. Only sufficient moisture to prevent adhesion
between the wheels of rollers and the mixture should be used. Surplus water shall not be allowed to stand on the
partially compacted pavement.
16.47.3.7 Joints : Where joints are made, the material shall be fully compacted and the joint made flush in
one of the following ways:
(a) All joints shall be cut vertical to the full thickness of the previously laid mix. All loosened material
shall be discarded and the vertical face coated with a suitable viscosity grade hot bitumen, or cold
applied emulsified bitumen. While spreading the material along the joint the material spread shall
overlap 25 mm to 50 mm on the previously laid mix beyond the vertical face of the joint. The
thickness of the loose overlap material should be approximately a quarter more than the final
compacted thickness. The overlapped mix shall be dragged back to the hot lane so that the roller
can press the small excess into the hot side of the joint to obtain a high joint density.
(b) By using two or more pavers operating in echelon, where this is practicable, and in sufficient proximity
for adjacent widths to be fully compacted by continuous rolling
All longitudinal joints shall be offset at least 300 mm from parallel joints in the layer beneath or as
directed, and in a layout approved by the Engineer-in-charge. Joints in the wearing course shall coincide with
either the lane edge or the lane marking, whichever is appropriate. Longitudinal joints shall not be situated in
wheel track zones.

16.47.3.8 Opening to Traffic : The newly laid surface shall not be open to traffic for at least 24
hours after laying the completion of compaction, without the approval of the Engineer-in-Charge in
writing.
16.47.3.9 Surface Finish and Quality Control of Work : The surface finish of the completed
of MORTH Specifications.
16.47.3.10 Arrangement for Traffic : During the period of construction, arrangements for traffic
shall be made in accordance with the provisions of specification and as per direction of the Engineer-
in-charge.
16.47.4 Measurement : Bituminous Macadam shall be measured as finished work in cubic meters
correct to two places of decimal.
16.47.5 Rate : The rate includes the cost of all material, labour, machineries and equipments in all
the operations described above.
16.48 DENSE BITUMINOUS CONCRETE

16.48.1 Scope
Dense Bituminous Concrete (DBC), is used in wearing and profile corrective courses. This work
shall consist of construction in a single layer of bituminous concrete on a previously prepared
bituminous bound surface. A single layer in a single layer shall be 30 mm / 40 mm / 50 mm thick.
16.48.2 Materials
16.48.2.1 Bitumen: The bitumen shall be viscosity grade paving bitumen complying with the Indian
Standard Specification IS:73, or as otherwise specified in the item. The type and grade of bitumen to
be used shall be specified in the item of Contract. Where modified bitumen is specified, it shall
conform to the requirements of IRC:SP:53 and IS:15462.
Section criteria for viscosity grade bitumen, based on highest and lowest daily mean temperatures
at a particular site are given in Table 16.40A.
Selection criteria for modified bitumen shall be in accordance with IRC:SP53.
16.48.2.2 Coarse Aggregates : Same as specified in para 16.46.2.2 excepting strength which shall
be max 30% for Los Angeles Abrasion Value and Aggregate Impact Value of max 24%. Where crushed
gravel is proposed for use as aggregate, not less than 95 percent by weight of the crushed material
retained on the 4.75 mm sieve shall have at least two fractured faces.
16.48.2.3 Fine Aggregates : The fine aggregates shall be all as specified in para16.46.2.3.
16.48.2.4 Filler : Filler shall be generally as specified in para 16.46.2.4.
16.48.2.5 Aggregate Grading and Binder Content : When tested in accordance with IS 2386
part 1 (wet grading method), the combined grading of the coarse and fine aggregates and added
filler shall fall within the limits shown in Table No. 16.42 for grading 1 or 2 specified in the contract.

TABLE NO. 16.42
Composition of Bituminous Concrete Pavement Layers
Grading 1 2
Nominal aggregate size* 19 mm 13.2 mm
Layer Thickness 50 mm 30-40 mm
IS Sieve1 (mm) Cumulative % by weight of total aggregate passing
45 - -
37.5 - -
26.5 100 -
19 90-100 100
13.2 59-79 90-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content % by mass of Min. 5.2* or as specified in Min. 5.4** or as specified in
total mix the item the item
Specified in item or directed Specified in item or directed
Bitumen grade
otherwise otherwise
* The nominal maximum particle size is the largest specified sieve size upon which any of the aggregate
is retained.
** Corresponds to specific gravity of aggregates being 2.7. In case aggregate have specific gravity
more than 2.7, the minimum bitumen content can be reduced proportionately. Further the region
where highest daily mean air temperature is 30º C or lower and lowest daily air temperature is – 10 º
C or lower, the bitumen content may be increased by 0.5 percent.
16.48.3 Mix Design

The bitumen content required shall be determined following the Marshall mix design procedure
contained in Asphalt Institute Manual MS-2.
The Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.
16.48.3.1 Requirements for the Mix : Same as specified in Para 16.46.3.1 shall apply.
16.48.3.2 Binder Content : Same as specified in para 16.46.3.2.
16.48.3.3 Job Mix Formula : The procedure for formulating the job mix formula shall be generally as
specified in Para 16.46.3.3.
16.48.3.4 Plant Trials – Permissible Variation In Job Mix Formula : The requirements for
plant trials shall be as specified in Para 16.46.3.4 and permissible limit for variation as given
in Table 16.43.

TABLE 16.43
Permissible Variations in the Plant Mix from the Job Mix Formula
Description Permissible Variation
Aggregate passing 19 mm sieve or larger ± 7%

Aggregate passing 13.2 mm, 9.5 mm ± 6%
Aggregate passing 4.75 mm ± 5%
Aggregate passing 2.36 mm, 1.18 mm, ± 4%
0.6 mm
Aggregate passing 0.3 mm, 0.15 mm ± 3%
Aggregate passing 0.075 mm ± 1.5%
Binder content ± 0.3%
Mixing temperature ± 10°C
16.48.3.5 Laying Trials : The requirements for laying trials be as specified in Para 16.46.3.5. The
compacted layers of bituminous concrete (BC) shall have a minimum field density equal to or more
than 92 percent of the average theoretical maximum specific gravity (Gmm) obtained on the day of
compaction in accordance with ASTM D2041.

16.48.4.1 Preparation of Base : The base on which DBC is to be laid shall be prepared, shaped and
compacted to the required profile as appropriate or as directed by the Engineer-in-charge. The
surface shall be thoroughly swept clean by a mechanical broom, and the dust removed by compressed
air, in locations where mechanical broom cannot get access, other approved methods shall be used
as directed by the Engineer-in-charge.
16.48.4.2 Tack Coat : Where the material on which the bituminous macadam is to be placed is
bitumen bound surface, a tack coat shall be applied as specified, in accordance with Para 16.29, or
as directed by the Engineer-in-Charge..
16.48.4.3 Mixing and Transportation of the Mixture : The provisions are same as specified in
Para 16.47.3.3 shall apply.
16.48.4.4 Spreading : The provisions are same as specified in Para 16.47.3.5 shall apply.
16.48.4.5 Rolling / Compaction : The provisions are same as specified in Para 16.47.3.6 shall
apply.
16.48.5 Opening to Traffic : The newly laid surface shall not be open to traffic for at least 24 hours
after laying the completion of compaction, without the approval of the Engineer-in-Charge in writing.
16.48.6 Surface Finish and Quality Control of Work : The surface finish of the completed
of MORTH Specifications
16.48.7 Arrangement for Traffic : During the period of construction, arrangements for traffic
shall be made in accordance with the provisions of specification and as per direction of the
Engineer-in-charge.
16.48.8 Measurement
Dense Bituminous Concrete shall be measured as finished work in cubic meters, correct to two
places of decimal.

16.48.9 Rate
The rate includes the cost of all material, labour, machineries and equipments in all the operations
described above.
16.49 RETRO REFLECTIVE SIGN BOARD

16.49.0 General
The colour, configuration, size and location of all the traffic signs for highways other than Express
ways shall be in accordance with the code of practice for road signs, IRC:67 or as shown on the
drawings. For expressways, the size of the signage, letters and their placement shall be as specified
in the contract drawings and relevant specifications or as directed by the Engineer-in-Charge.
16.49.1 Materials
16.49.1.1 Concrete
Concrete shall be of M-25 grade.
16.49.1.2 Reinforcing steel

Reinforcing steel shall confirm to the requirement of IS 1786 unless otherwise specified.
16.49.1.3 Bolts Nuts and Washers

High strength bolts shall confirm to IS 1367 whereas precision bolts, nuts etc. shall confirm to IS 1364.
16.49.1.4 Plates and Supports

Plates and support sections for the sign posts shall confirm to IS 226 and IS 2062 or any other
stated IS specification.
16.49.1.5 Substrata
The substrate shall be either aluminium sheeting or aluminium composite material (ACM) confirming
to following sub-sections.
16.49.1.5.1 Aluminium
Aluminium sheets used for sign boards shall be of smooth, hard and corrosion resistant aluminium
alloy confirming to IS 736 material designation 24345 or 1900.
16.49.1.5.2 Aluminium composite materials

(i) The Aluminum Composite Material (ACM), used as the substrate for signage application
shall have a thickness of at least 4.0mm (excluding coating thickness).
(ii) The ACM shall be composed of thermoplastic core of “Low Density Polyethylene’ (LDPE) of
3.0mm thickness sandwiched between two thick sheets of aluminium, of 3003 grade and H-
18 temper and minimum thickness of 0.5mm each. The retro reflection sheeting must be
applied on the top surface with aluminium surface with recommended surface preparation
from sheeting manufactures.
(iii) A fluorocarbon coating may be applied over the exposed surface of aluminum to ensure
corrosion resistance and weather proof and thus shall confirm to relevant ASTM.
(iv) The ACM shall have a high-surface energy coating on the top surface, over which the retro
reflective sheeting shall be applied.
(v) When measured after 24 hrs after application, the 90 peel-adhesion strength of the top
surface of ACM with the retro reflective sheeting applied on it using a 2kg roller as per
ASTM D3330 shall be at least 1.5 kg-f.

(vi) The front surface shall have no other coating other than the high-surface energy coating
and shall be protected with a self-adhesive peel-off film. The retro refletive sheeting shall
be applied only on the top surface with high-surface energy coating.
(vii) On the back surface, it shall have a polyester based service coating preferably grey in color
to protect against possible corrosion and to avoid undesired glare from the rear side of the
sign.
(viii) The mechanical properties of 4mm ACM and that of its aluminium skim shall confirm to the
requirement given in table 16.44 below. When tested accordance with the test methods
mentioned against each of them.
Table 16.44
Specification for Aluminium Composite Material (ACM)
S. No. Description Specification for 4mm
Standard Test Acceptable Value/Results
A Physical Tests for ACM
1 Over all thickness of ACM Measurement 4mm (Tolerance + 0.2mm)
2 Aluminium Skin thickness Measurement 0.5mm (Tolerance +/- 0.03mm)
(each side)
Panel weight (ACM) Measurement 5.5 Kg/m2 (+ 5%)
B Mechanical Properties of ACM
1 Peel off strength with retro ASTM D903 Min. 4 N/mm
reflective sheeting. (Drum Peel
Test)
2 Tensile strength ASTM E638 Min. 40 N/mm2
3 0.2% Proof Stress ASTM E638 Min. 34 N/mm2
4 Elongation ASTM E638 Min. 6%
5 Flexural strength ASTM C393 Min. 130 N/mm2
5 Shear strength with punch ASSTM D732 Min. 18 N/mm2
shear test
C Properties of Aluminium skin
1 Tensile strength (Rm) ASTM E8 Min. 150 N/mm2
2 Modules of elasticity ASTM E8 Min 70000 N/mm2
3 Elongation ASTM E8 A50 Min. 2%
4 0.2% proof stress ASTM E8 Min. 110 N/mm2
D Properties of High surface
energy coating
1 (90 deg) Peel adhesion ASTM D330 Min. of 1.5 kgf
strength of Retroreflective i.e. Equal to or more than that with
sheeting on ACM surface with surface prepared aluminium
high-surface energy coating
16.49.1.5.3 Performance Certificate

Requisite performance certificate from the manufacturer of the ACM stating compliance with ACM
technical specification as per Table 16.44 above shall be submitted by the contractor to the Engineer-
in-Charge.
16.49.1.6 Retro- Reflective Sheeting (Type-XI Prismatic Grade sheeting):

(AS per IRC 67-2012 Clause 6.7)
The retro reflective sheeting used on the signs shall consist of white or coloured sheeting having
a smooth outer surface which has the property of retro reflection over its entire surface. It shall be
weather resistant and exhibit colour fastness. It shall be new and unused and show no evidence of
cracking, scaling, and pitting, blistering, edge lifting or curling and shall have negligible shrinkage or
expansion. A certificate of having the sheeting tested for coefficient of retro reflection, daytime colour

and luminance, shrinkage, flexibility, liner removal, adhesion, impact resistance, specular gloss and
fungus resistance, 3 years outdoor weathering and its having passed these tests shall be obtained
from International / Government Laboratory / Institute by the manufacturer of the sheeting and in
case the certificate is obtained from international agency, it should also be obtained from Indian
agency within 3 years of launching of product by the manufacture in abroad. Alternatively, a certificate
conforming to ASTM Specification (D 4956-09) on artificial accelerated weathering requirements
from a reputed laboratory in India can be accepted provisionally. In such a situation, the Employer/
Client, if so desires, could seek for a performance guarantee which would be released after receipt
of certificate meeting the requirement of three years outdoor weathering of the sheeting.
Retro-reflective sheeting is typically manufactured as a cube corner. The reflective sheeting

shall be retro-reflective sheeting made of micro prismatic retro-reflective material. The retro-reflecting
surface after cleaning with soap and water and in dry condition shall have minimum co-efficient of
retro reflection (determined in accordance with ASTM D4956-09) confirming to IRC:67 Table 6.9.
When totally wet, the sheeting shall not show less than 90 per cent of the values of retro-reflection.
At the end of 10 years the sheeting shall return at least 80 per cent of its original retro-reflectance.
16.49.1.7 Adhesives : The sheeting shall have a pressure-sensitive adhesive of the aggressive-
tack type requiring no heat, solvent or other preparation for adhesion to a smooth clean surface, in
a manner recommended by the sheeting manufacturer and approved by Engineer-in-Charge. The
adhesive shall be protected by an easily removable liner (removable by peeling without soaking in
water or other solvent) and shall be suitable for the type of material of the base plate used for the
sign. The Adhesive shall form a durable bond to smooth, corrosion and weather resistant surface of
the base plate such that it shall not be possible to remove the sheeting from the sign base in one
piece by use of sharp instrument. The sheeting shall be applied in accordance with the manufacturers
specifications.
16.49.2 Installation
16.49.2.1 Surface to be reflectorised shall be effectively prepared to receive the retro- reflective
sheeting. The Aluminium / ACP sheeting shall be de-greased either by acid or hot alkaline etching
and all scale/dust removed to obtain a smooth plain surface before the application of retro-reflective
sheeting. Complete sheet of the material shall be used on the signs except where it is unavoidable.
Sheeting with heat-activated adhesives may be spliced with an overlap not less than 5 mm or butted
with a gap not exceeding 0.75 mm. The material shall cover the sign surface evenly and shall be free
from twists, cracks and folds.
16.49.2.2 Sign posts, their foundations and sign mountings shall be so constructed as to hold these
in a proper and permanent position against the normal storm wind load or displacement by vandalism.
Normally, sign with an area upto 0.9 sq.m shall be mounted on a single post and for greater area two
or more supports shall be provided. Sign supports shall be as specified in item or as per directions of
Engineer-in-Charge. The work of foundation shall conform to relevant specification as specified.
16.49.2.3 Backside of aluminium sheet portion shall be painted with two coats of epoxy paint. Any
part and support frame with two or more coats of synthetic enamel paint.
16.49.3 Performance Certificate

Requisite performance certificate from the manufacturer of the ACM stating compliance with ACM
technical specification as per Table 16.44 above shall be submitted by the contractor to the Engineer-
in-Charge.

16.49.4 Warranty and Durability
The Contractor shall obtain from the manufacturer a ten year warranty as per IRC:67 for
satisfactory performance including stipulated retro-reflectance of the retro-reflective sheeting, the
screen printed areas and cut out sheeting and cut out durable transparent overlay film and submit
the same to the Engineer-in-Charge.
Processed and applied in accordance with recommended procedures, the reflective material
shall be weather resistant and following cleaning, shall show no appreciable discoloration, cracking,
blistering or dimensional change and shall not have less than 50 percent of the specified minimum
reflective intensity values when subjected to accelerated weathering of 1000 hours, using type E or
EH Weather meter (AASHTO Designation M 268).
16.49.5 Measurement
These shall be measured in square meters upto two place of decimal.
16.49.6 Rate
The rate includes the cost of materials labour and equipments involved in all the operations
described above except 16.49.1.1 to 16.49.1.4.
16.50 RETRO REFLECTIVE OVERHEAD SIGNAGE

16.50.0 General
Overhead signs may be used in lieu of, or as an adjunct to, ground signs where the situation so
warrants for proper information and guidance of the road user.
The support system should be properly designed based on sound engineering principles, to
safety sustain the dead load, live load and wind load on the completed sign system. For this purpose,
the overhead signs shall be designed to withstand a wind loading of 150 kg/m2 normal to the face of
the sign and 30 kg/m2 transverse to the face of the sign. In addition to the dead load of the structure,
walkway loading of 250kg concentrated live load shall also be considered for the design of the
overhead sign structure.
16.50.1 Height
Overhead signs shall provide a vertical clearance of not less than 5.5 m over the entire width of
the pavement and shoulders except where a lesser vertical clearance is used for the design of other
structures. The vertical clearance to overhead sign structures or supports need not to be greater
than 300 mm in excess of the minimum design clearance of other structures.
16.50.2 Lateral Clearance

16. 50.2.1 The minimum clearance outside the usable roadway shoulder for expressway sign mounted
at the road side or for overhead sign supports either to the right or left side of the roadways shall be
1.80 m. This minimum clearance of 1.80 m shall also apply outside of an unmountable kerb. Where
practicable, a sign should not be less than 3 m from the edge of the nearest traffic lane.
16.50.2.2 Where a median is 3.6 m or less in width, consideration should be given to spanning over
both roadways without a central support. Where overhead sign supports cannot be placed at a safe
distance away from the line of traffic or in an otherwise protected site, they should either be so
designed as to minimize the impact forces or protect motorists adequately by a physical barrier or
guard rail of suitable design.
16.50.3 Number of Signs at an Overhead Installation

In no case should there be more than three signs displayed at any one location, including regulatory
or warning signs, either on the overhead structure or on its support.

16.50.4 Materials for Overhead Sign and Support Structures
16.50.4.1 Aluminium alloy or galvanized steel to be used as truss design supports shall conform to
relevant IS. These shall be of sections and type as per structural design requirements as shown on
the plans.
16.50.4.2 Plates and support sections for sign posts shall conform to IS 226 and IS 2062.
16.50.4.3 The overhead signs shall be reflectorised with high intensity retro-reflective sheeting of
encapsulated lens type.
16.50.5 Size, Locations, etc of Signs

16.50.5.1 The size of the signs, letter and their placement shall be as specified in the Contract
drawings and specifications as per direction of Engineer-in-Charge.
16.50.6.1 The supporting structure and signs shall be fabricated and erected as per details given in
the plans.
16.50.6.2 Sign posts, their foundations and sign mountings shall be so constructed as to hold sign in
a proper and permanent position to adequately resist swaying in the wind or displacement by vandalism.
16.50.6.3 The work of construction of foundation for sign supports including excavation and backfill,
forms, steel reinforcement, concrete and its placement shall conform to the relevant specifications
given in this specification.
16.50.6.4 The structures shall be erected with the specified camber and in such a manner as to
prevent excessive stresses, injury and defacement.
16.50.6.5 Brackets shall be provided for mounting signs of the type to be supported by the structure.
For better visibility, they shall be adjustable to permit mounting the sign faces at any angle between
a truly vertical position and three degree from vertical. This angle shall be obtained by rotating the
front lower edge of the sign forward. All brackets shall be of a length equal to the heights of the signs
being supported.
16.50.6.6 Before erecting support structures, the bottom of each base plate shall be protected with
an approved material which will adequately prevent any harmful reaction between the plate and the
concrete.
16.50.6.7 The end supports shall be plumbed by the use of levelling nuts and the space between the
foundation and base plate shall be completely filled with an anti-shrink grout.
16.50.6.8 Anchor bolts for sign supports shall be set to proper locations and elevation with templates
and carefully checked after construction of the sign foundation and before the concrete has set.
16.50.6.9 All nuts on aluminium trusses, except those used on the flanges, shall be tightened only
until they are snug. This includes the nuts on the anchor bolts. A thread lubricant shall be used with
each aluminium nut.
16.50.6.10 All nuts on galvanized steel trusses, with the exception of high strength bolt connections,
shall be tightened only to a snug condition.
16.50.6.11 Field welding shall not be permitted.

16.50.6.12 After installation of signs is completed; the sign shall be inspected by the Engineer. If
specular reflection is apparent on any sign, its positioning shall be adjusted by the Contractor to
eliminate or minimize this condition.
16.50.7 Measurement
These shall be measured in sq.meter upto two place of decimal.
16.50.8 Rate
The rate includes the cost of materials, labour and equipments involved in all the operations
described above.
16.51 ROAD MARKINGS STRIPS

The colour width and layout of road makings shall be in accordance with the Code of Practice for
Road Markings with paints, IRC : 35, and as specified in the drawings or as directed by the Engineer-
in-Charge.
16.51.1 Materials
Road markings shall be of ordinary road marking paint (retro-reflective), hot applied
thermoplastic compound as specified in the item.
16.51.2 Hot Applied Thermoplastic Road Marking

General
(i) The thermoplastic material shall be homogenously composed of aggregate, pigment, resins
and glass reflectorizing beads.
(ii) The thermoplastic compound shall be screeded/extruded on to the pavement surface in a
molten state by suitable machine capable of controlled preparation and laying with surface
application of glass beads at a specific rate. Upon cooling to ambient pavement temperature,
it shall produce an adherent pavement marking of specified thickness and width and capable
of resisting deformation by traffic.
(iii) The thermoplastic material shall conform to ASTM D36/BS-3262-(Part I).
(iv) The material shall meet the requirements of these specifications for a period of one year.
The thermoplastic material must also melt uniformly with no evidence of skins or unmelted
particles for the one year storage period. Any material not meeting the above requirements
shall be replaced by the manufacturer/supplier/Contractor.
(v) Marking : Each container of the thermoplastic material shall be clearly and indelibly marked
with the following information:
1. The name, trade mark or other means of identification of manufacturer.
2. Batch number
3. Date of manufacture
4. Colour (White or yellow)
5. Maximum application temperature and maximum safe heating temperature.
(vi) Sampling and Testing : The thermoplastic material shall be sampled and tested in
accordance with the appropriate ASTM/BS method. The Contractor shall furnish to the
Engineer-in-Charge a copy of certified test reports from the manufacturers of the thermoplastic
material showing results of all tests specified herein and shall certify that the material meets
all requirements of this Specification.

16.51.3 Preparation
(i) The material shall be melted in accordance with the manufacturer’s instructions in a heater
fitted with a mechanical stirrer to give a smooth consistency to the thermoplastic material to
avoid local overheating. The temperature of the mass shall be within the range specified by
the manufacturer, and shall on no account be allowed to exceed the maximum temperature
stated by the manufacturer. The molten material should be used as expeditiously as possible
and for thermoplastic material which has natural binders or is otherwise sensitive to
prolonged healing, the material shall not be maintained in a molten condition for more than
4 hours.
(ii) After transfer to the laying equipment, the material shall be maintained within the temperature
range specified by the manufacturer for achieving the desired consistency for laying.
6.51.4 Properties of Finished Road Marking

(a) The stripe shall not be slippery when wet.
(b) The marking shall not lift from the pavement in freezing weather.
(c) After application and proper drying, the stripe shall show no appreciable deformation or
discolouration under traffic and under road temperatures upto 60oC.
(e) The marking shall not deteriorate by contact with sodium chloride, calcium chloride or oil
drippings from traffic.The stripe or marking shall maintain its original dimensions and position.
Cold ductility of the material shall be such as to permit normal movment with the road
surface without chopping or cracking.
(f) The colour of yellow marking shall conform to IS Colour No. 356 as given in IS 164.
16.51.5 Application
Marking shall be done by fully /semi automatic paint applicator machine fitted with profile shoe,
glass beads dispenser, propane tank heater and profile shoe heater, driven by experienced operator
as specified in item. For locations where painting cannot be done by machine, approved manual
methods shall be used with prior approval of the Engineer-in-charge. The Contractor shall maintain
control over traffic while painting operations are in progress so as to cause minimum inconvenience
to traffic compatible with protecting the workmen.
The thermoplastic material shall be applied hot either by screeding or extrusion process. After
transfer to the laying apparatus, the material shall be laid at a temperature within the range specified
by the manufacturer or otherwise directed by the Engineer-in-Charge for the particular method of
laying being used. The paint shall be applied using a screed or extrusion machine.
The pavement temperature shall not be less than 10oC during application. All surfaces to be
marked shall be thoroughly cleaned of all dust, dirt, grease, oil and all other foreign matter before
application of the paint.
Thermoplastic paint shall be applied in intermittent or continuous lines of uniform thickness of at

least 2.5 mm unless specified otherwise. Where arrows or letters are to be provided, thermoplastic
compound may be hand-sprayed.
The minimum thickness specified is exclusive of surface applied glass beads.
The finished lines shall be free from ruggedness on sides and ends and be parallel to the
general alignment of the carriageway. The upper surface of the lines shall be level, uniform and
free from streaks.

16.51.6 Measurements for Payment
The painted markings shall be measured in sq. metres of actual area marked (excluding the
gaps, if any) correct upto the two places of decimal.
16.51.7 The rate include the cost of all materials, labour and equipments required in all the above
operations.
16.52 KERB CHANNEL OF CEMENT CONCRETE

Base : The base of the channel to be of the 75 mm compacted thick dry brick ballast 40 mm
nominal size well rammed and consolidated and grouted with fine sand.
Kerb channel shall be provided in cement concrete of specified grade. These shall be cast in-situ
of specified size as given in the item. Top surface of channel to be finished smooth.
Measurements : Cement concrete channel shall be measured in metre of length of the completed
channel correct upto two places of decimal.
Rate : The rate includes the cost of all the materials, labours and tools required in all the operations
described above.
16.53 75 MM THICK COMPACTED BED OF DRY BRICK BALLAST

16.53.1 Collection of Material
Before the start of work brick aggregate 40 mm nominal size unless specified otherwise, shall be
stacked for the entire work and record measurements done as per para 16.4.
16.53.2 Preparation of Sub Grade

The formation for a width equal to that of the area shall be cut to the depth below the proposed
finish level, equal to the thickness of the course of brick aggregate (due allowance being made for
consolidation) and dress off in level to the finished profile. In case of made up soil, copious water
shall be poured so that earth settles down as much as possible and the same rolled up with 3 tonnes
or light power roller, as directed by the Engineer-in-Charge.
16.53.3 Laying and Packing Brick Aggregate

Brick aggregate shall be racked off the stack with the racks so as to leave behind mud and
dust. It shall be spread evenly over the prepared surface to the required depth with a finishing
material to avoid segregation. Brick aggregate shall be carefully laid and packed, bigger size
being placed at the bottom to 7.5 cm. depth unless specified otherwise. After that the area shall be
grouted with fine sand.
16.53.4 Consolidation
The bricks aggregate shall be consolidated by dry rolling with 3 tonne or light weight power roller
as directed by the Engineer-in-Charge.
16.53.5 Measurement
The measurement of the finished work shall be taken in sqm. correct to two places of decimal.
Length and breadth shall be measured in metre correct to a centimeter.
16.53.6 Rate
Rate includes the cost of all the materials, labour and equipment required in all the operations as
described above.

16.54 POST DELINEATORS
16.54.1 The role of delineators is to provide visual assistance to drivers about alignment of the road
ahead, especially at night. Delineators are particularly effective in the case of complex locations
involving changes in horizontal / vertical geometry and doing severe weather condition such as
heavy rain, fog or snow. Normally reflectors are used on the delineators for better night time visibility.
Road delineators may have a circular, rectangular or triangular cross-section, however the side
facing the traffic should not be less than 10 cm wide.
In board sense, Delineators stands for any device or treatment whose aim is to outline the road way.
16.54.2 Material :
The design, materials to be used and the location of the road delineators shall conform to
recommended practice for road delineators, IRC:79, and to relevant drawings and as directed by the
Engineer-in-charge.
The delineators are to be made of Acrylonitrite Butadiene Styrene (ABS) body fitted with 2 No.
100 mm dia of highly reflective reflectors are mounted on M.S. pipe of 65 mm dia or of size specified
otherwise, duly powder coated of minimum 40 microns thickness anti-rust and anti-theft, installed as
per direction of Engineer-in-charge. Road delineators may have a circular, rectangular or triangular
cross-section, however the side facing the traffic should not be less than 10 cm wide.
16.54.3 Dimensions :
Height of the delineator should be not less than 800 mm above ground. Width not less than 100
mm. Not more than 300 mm below the ground while being installed.
16.54.4 Placement and spacing :

As a general rule, delineators posts should be erected at the edge of the usable shoulders, and
in the case of kerbed sections at a distance of 0.6 to 1.5 m from the kerb face. On hill roads they may
be placed either on the parapet or at the edge of the shoulders.
The delineator should be so positioned that the reflectorised face is perpendicular to the direction
of travel.
Warranty :
The contractor shall obtain a two years warranty for satisfactory performance including stipulated
retro-reflectance of the retro-reflective sheeting and submit the same to the Engineer-in-charge.
16.54.5 Measurement
The measurement shall be made in numbers of delineators fixed at site.
16.54.6 Rate
The rate include the cost of all the material, labour and equipments required in all the operations
described above.
16.55 EXCAVATING HOLES UPTO 0.10 CUM

The specifications of sub head earth work of CPWD specifications 2019 Vol-I to be followed for
this item.
16.56 FACTORY MADE RCC PAVEMENT SLAB

Precast RCC slab casted with the cement concrete of M-30 or specified otherwise grade of size
specified in item made of approved brand and manufacturer to be used.
Specification of cement concrete base, bed cement mortar and RCC to be of the sub head
cement concrete, mortar and RCC of the CPWD specification- 2019 Vol- I to be followed.

16.57 FACTORY MADE CEMENT CONCRETE INTERLOCKING PAVER BLOCK
16.57.1 Base
Interlocking paver block to be fixed on the bed 50 mm or specified otherwise thick of coarse sand
of approved specification and filling the joints with the sand of approved type and quality or as
specified and as directed by Engineer-in-charge.
16.57.2 Interlocking Paver Block

Factory made precast paver block of M-30 or otherwise specified grade to be used. Paver
blocks to be of approved brand and manufacturer and of approved quality. Minimum strength as
prescribed by manufacturer and as per direction of Engineer-in-Charge for the grade specified to
be tested as per method mentioned in specification of subhead cement concrete of CPWD
Specification 2019 Vol. I.
16.57.3 Measurement & Rates

Area provided with paver block to be measured in sqm. correct upto two places of decimal. The
rate include the cost of the material, labour, tools etc. required in all the operations described above.
16.58 KERB STONE (PRECAST)
16.58.1 Laying
16.58.1.1 Trenches shall first be made along the edge of the wearing course of the road to receive
the kerb stones of cement concrete of specified grade. The bed of the trenches shall be compacted
manually with steel rammers to a firm and even surface and then the stones shall be set in cement
mortar of specified proportion.
16.58.1.2 The kerb stones with top 20 cm. wide shall be laid with their length running parallel to the
road edge, true in line and gradient at a distance of 30 cm. from the road edge to allow for the
channel and shall project about 12.5 cm. above the latter. The channel stones with top 30 cm. wide
shall be laid in position in chamber with finished road surface and with sufficient slope towards the
road gully chamber. The joints of kerb and channel stones shall be staggered and shall be not more
than 10 mm. Wherever specified all joints shall be filled with mortar 1:3 (1 cement : 3 coarse sand)
and pointed with mortar 1:2 (1 cement: 2 fine sand) which shall be cured for 7 days.
16.58.1.3 The necessary drainage openings of specified sizes shall be made through the kerb as
per drawings or as directed by the Engineer-in-Charge for connecting to storm water drains.
16.58.2 Finishing
Berms and road edges shall be restored and all surplus earth including rubbish etc. disposed off
as directed by the Engineer-in-charge. Nothing extra shall be paid for this.
It shall be measured in cubic meters with Length of the finished work (for specified width and
height of stone) shall be measured in running metre along the edge of the road correct to a cm.
16.58.4 Rate
The rate shall include the cost of all the materials and labour involved in all the operations
described above.
16.59 G.I. CHAIN LINK FABRIC FENCING

16.59.1 Material
G.I. Chain link fabric fencing of required width in mesh size 50 x 50 or 25 x 25 mm or specified
otherwise of approved brand and made of specified dia GI wire PVC coated of specified thickness /
or not as specified in item of required colour or shade to be used.

16. 59.1.1 Fixing : GI chain link shall be stretched and fixed in specified width, strengthening with 2
mm dia wire or nuts bolts & washers as required to be done complete as per the direction of Engineer-
in-Charge.
16.59.1.2 Measurements : The length and width shall be measured correct to a cm. The area shall
be calculated in square metre, correct to two places of decimal.
16.59.2 The rate shall include the cost of material and labour involved in all the operations described
as above.
16.60 SUPPLYING AND STACKING OF HARD STONE (FOR STONE PITCHING)

Hard stone hammer dressed having no side less than 15 cm. with minimum depth of 20 cm. of the
specification as mentioned in subhead - stone work of CPWD Specification- 2019 Vol. I to be used.
Specification for supplying, stacking and measurement to be same as for item no. 16.3.
16.61 VACUUM DEWATERED CEMENT CONCRETE PAVEMENT

16.61.1 Cement concrete to be compacted by screed board vibrator of the type approved by Engineer-
in-Charge and by vaccum dewatering process complete as per directions of Engineer-in-charge.
It shall be measured in cubic meteres correct to two place of decimal.
16.61.3 Rate
The rate shall include the cost of material, labour and machinery involved in all the operations
described above.
16.62. GRANULAR SUB–BASE

16.62.1. Scope
This work shall consist of laying and compacting well-graded material on prepared subgrade in
accordance with the requirements of these Specifications. The material shall be laid in one or more
layers as sub-base or lower sub-base and upper sub-base (termed as sub-base hereinafter) as
necessary according to lines, grades and cross-sections shown on the drawings or as directed by
the Engineer-in-charge.
16.62.2. Materials
16.62.2.1. The material to be used for the work shall be natural sand, crushed gravel, crushed
stone, crushed slag or combination thereof depending upon the grading required. Use of materials
like brick metal, Kankar and crushed concrete shall be permitted in the lower sub-base. The material
shall be free from organic or other deleterious constituents and shall conform to the grading given in
Table 16.44 and physical requirement given in Table 16.45 Gradings III and IV shall preferably be
used in lower sub-base. Grading V and VI shall be used as a sub-base-cum-drainage layer. The
grading to be adopted for a project shall be as specified in the Contract. Where the sub-base is laid
in two layers as upper sub-base and lower sub-base, the thickness of each layer shall not be less
than 150 mm.
16.62.2.2 If the water absorption of the aggregate determined as per IS : 2386 (Part 3); if this
value is greater than 2 per cent, the aggregate shall be tested for Wet Aggregate Impact Value
(AIV) (IS: 5640). Soft aggregates like Kankar, Brick ballast and laterite shall also be tested for
Wet AIV (IS: 5640).

TABLE No. 16.44
GRADING FOR GRANULAR SUB-BASE MATERIALS
IS Sieve Percent by Weight Passing the IS Sieve
Designation Grading I Grading II Grading III Grading IV Grading V Grading VI
75.0 mm 100 -- -- -- 100 --
53.0 mm 80-100 100 100 100 80-100 100
26.5 mm 55-90 70-100 55-75 50-80 55-90 75-100
9.50 mm 35-65 50-80 -- -- 35-65 55-75
4.75 mm 25-55 40-65 10-30 15-35 25-50 30-55
2.36 mm 20-40 30-50 -- -- 10-20 10-25
0.85 mm -- -- -- -- 2-10 --
0.425 mm 10-15 10-15 -- -- 0-5 0-8
0.075 mm <5 <5 <5 <5 -- 0-3
TABLE No. 16.45

PHYSICAL REQUIREMENTS FOR MATERIALS FOR GRANULAR SUB-BASE
Aggregate Impact Value (AIV) IS:2386 (Part 4) or IS:5640 40 Maximum
Liquid Limit IS:2720 (Part 5) Maximum 25
Plasticity Index IS:2720 (Part 5) Maximum 6
CBR at 98% dry density (at IS:2720 (Part 5) Minimum 30 unless otherwise
IS:2720-Part 8) specified in the Contract

16.62.3.1. Preparation of Sub-Grade:
The surface of the sub grade to receive the Granular Sub-base shall be prepared to the specified
lines and crossfall (Camber) as necessary and made free of dust and other extraneous materials.
Any ruts or soft yielding places shall be corrected in an approved manner and rolled with 80 – 100 kN
smooth wheeled roller until firm surface is obtained if necessary by sprinkling water. Weak places
shall be strengthened, corrugations removed and depressions and pot holes made good with suitable
materials, before spreading the aggregate for GSB.
Where the existing surface over which the sub base of GSB is to be laid is black topped, to
ensure effective internal drainage, furrows 50 mm x 50 mm (depth of furrows increased to reach
bottom of bituminous layer where necessary) at one metre intervals shall be cut in the existing
bituminous surface at 45 degrees to the central line of the carriageway at one metre intervals in the
existing road before the GSB is laid.
16.62.3.2 Spreading and compacting:

The sub-base material of grading specified in the Contract and water shall be mixed mechanically
by a suitable mixer equipped with provision for controlled addition of water and mechanical mixing.
So as to ensure homogenous and uniform mix. The required water content shall be determined in
accordance with IS:2720 (Part 8). The mix shall be spread on the prepared sub-grade with the help
of a motor grader of adequate capacity, its blade having hydraulic controls suitable for initial adjustment
and for maintaining the required slope and grade during the operation, or other means as approved
Moisture content of the mix shall be checked in accordance with IS:2720 (Part 2) and suitably
adjusted so that, at the time of compaction, it is from 1 to 2 per cent below the optimum moisture
content (OMC).

Immediately after spreading the mix, rolling shall be done by an approved roller. If the thickness of the
compacted layer does not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For
a compacted single layer upto 200 mm the compaction shall be done with the help of a vibratory roller of
minimum 80 to 100 kN static weight capable of achieving the required compaction. Rolling shall commence at
the lower edge and proceed towards the upper edge longitudinally for portions having unidirectional crossfall or
on super elevation. For carriageway having crossfall on both sides, rolling shall commence at the edges and
progress towards the crown.
Each pass of the roller shall uniformly overlap not less than one third of the track made in the preceding
pass. During rolling, the grade and crossfall (camber) shall be checked and any high spots or depressions,
which become apparent, corrected by removing or adding fresh material. The speed of the roller shall not
exceed 5 km per hour.
Rolling shall be continued till the density achieved is at least 98 percent of the maximum dry density for
the material determined as per IS : 2720 (Part 8). The surface of any layer of material on completion of
compaction shall be well closed, free from movement under compaction equipment and from compaction
planes, ridges, cracks or loose material. All loose, segregated or otherwise defective areas shall be made
good to the full thickness of layer and re-compacted.
Granular sub-base shall be measured as finished work in position in cubic metres. The length and breadth
shall be measured to the nearest centimetre. The depth of consolidated layer shall be computed to nearest half
centimetre by taking average of depths at the centre and at 30 cm from the left and right edges at a cross section
taken at 100 metre interval or less as decided by the Engineer-in-Charge by making small pits. The consolidated
cubical contents shall be calculated in cubic metres correct to two places of decimal. The protection of edges of
granular sub-base extended over the full formation as shown in the drawing shall be considered incidental to the
work of providing granular sub-base and as such no extra payment shall be made for the same.
16.62.5. Rate
The Contract unit rate for granular sub-base shall be payment in full for carrying out the required operations
including all labour, tools, equipments, machinery and incidentals to complete the work to the specifications
as described above.
16.63. WET MIX MACADAM (WMM) SUB-BASE/BASE

16.63.1 Scope
This work shall consist of laying and compacting clean, crushed, graded aggregate and granular
material, premixed with water, to a dense mass on a prepared subgrade/sub-base/base or existing pavement as
the case may be in accordance with the requirements of these Specifications. The material shall be laid in one
or more layers as necessary to lines, grades and cross-sections shown on the approved drawings or as directed
The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75 mm. When vibrating
or other approved types of compacting equipment are used, the compacted depth of a single layer of the sub-
base course may be increased to 200 mm upon approval of the Engineer-in-charge.
16.63.2.Materials
16.63.2.1. Aggregates
16.63.2.1.1. Physical requirements
Coarse aggregates shall be crushed stone. If crushed gravel/shingle is used, not less than 90
per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall have at least two
fractured faces. The aggregates shall conform to the physical requirements set forth in Table
16.46 below.
If the water absorption value of the coarse aggregate is greater than 2 per cent, the soundness test shall
be carried out on the material delivered to site as per IS:2386(Part-5).

TABLE 16.46
PHYSICAL REQUIRMENTS OF COARSE AGGREGATES FOR SUB-BASE/BASE COURSES
Test Test Method Requirement
1. Los Angeles IS:2386 (Part-4) 40 per cent (Max.)
Abrasion value
or
Aggregate impact value IS:2386 (Part-4) or IS:5640 30 per cent (Max.)
2. Combined Flakiness and IS:2386 (Part-1) 35 per cent (Max.)*
Elongation indices (Total)
* To determine this combined proportion, the flaky stone from a representative sample should
first be separated out. Flakiness index is weight of flaky stone metal divided by weight of
stone sample. Only the elongated particles be separated out from the remaining (non-flaky)
stone metal. Elongation index is weight of elongated particles divided by total non-flaky
particles. The value of flakiness index and elongation index so found are added up.
16.63.2.1.2. Grading requirements :

The aggregates shall conform to the grading given in Table 16.47 below.
TABLE 16.47
GRADING REQUIREMENTS OF AGGREGATES FOR WET MIX MACADAM
IS Sieve Designation Per cent by weight passing the IS sieve
53.00 mm 100
45.00 mm 95-100
26.50 mm ---
22.40 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-5
Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.
The final gradation approved within these limits shall be well graded from coarse to fine and shall
not vary from the low limit on one sieve to the high limit on the adjacent sieve or vice versa.
16.63.3. Construction Operations

16.63.3.1. Preparation of base :
The surface of the sub grade / sub base / base to receive the Wet Mix Macadam shall be prepared
to the specified lines and crossfall (Camber) as necessary and made free of dust and other extraneous
materials. Any ruts or soft yielding places shall be corrected in an approved manner and rolled with
80-100 kN smooth wheeled roller until firm surface is obtained if necessary by sprinkling water. Weak
places shall be strengthened, corrugations removed and depressions and pot holes made good with
suitable materials, before spreading the aggregate for WMM.
Where the existing surface over which the sub base of WMM is to be laid is black topped, to
ensure effective internal drainage, furrows 50 mm x 50 mm (depth of furrows increased to reach
bottom of bituminous layer where necessary) at one metre intervals shall be cut in the existing
bituminous surface at 45 degrees to the central line of the carriageway at one metre intervals in the
existing road before the WMM is laid.

16.63.3.2. Provision of lateral confinement of aggregates:
While constructing wet mix macadam, arrangement shall be made for the lateral confinement of
wet mix. This shall be done by laying materials in adjoining shoulders along with that of wet mix
macadam layer.
16.63.3.3. Preparation of mix:

Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity having
provision for controlled, addition of water and forced/positive mixing arrangement like pugmill or pan
type mixer of concrete batching plant. For small quantity of wet mix work, the Engineer may permit
the mixing to be done in concrete mixers.
Optimum moisture for mixing shall be determined in accordance with IS:2720 (Part-8) after replacing
the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size. While
adding water, due allowance should be made for evaporation losses. However, at the time of
compaction, water in the wet mix should not vary from the optimum value by more than agreed limits.
The mixed material should be uniformly wet and no segregation should be permitted.
16.63.3.4. Spreading of mix :

Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the prepared
subgrade/sub- base/base in required quantities. In no case should these be dumped in heaps directly
on the area where these are to be laid nor shall their hauling over a partly completed stretch be
permitted.
The mix may be spread either by a paver finisher.
The paver finisher shall be self-propelled of adequate capacity with the following features:
(i) Loading hoppers and suitable distribution system. So as to provide a smooth uninterrupted
material flow for different layer thickness from the tipper to the screed.
(ii) Hydraulically operated telescopic screed for paving width upto 8.5 metre and fixed screed
beyond this. The screed shall have tamping and vibrating arrangement for initial compaction
of the layer.
(iii) Automatic leveling control system with electronic sensing device to maintain mat thickness
and cross slope of mat during laying procedure. In exceptional cases where it is not possible
for the paver to be utilized mechanical means like motor grader may be used with the prior
approval of the Engineer-in-charge. The motor grader shall be capable of spreading the
material uniformly all over the surface.
The surface of the aggregate shall be carefully checked with templates and all high or low spots
remedied by removing or adding aggregate may be required. The layer may be tested by depth
blocks during construction. No segregation of larger and fine panicles should be allowed. The
aggregates as spread should be of uniform gradation with no pockets of fine materials.
The Engineer-in-charge may permit manual mixing and / or laying of Wet Mix Macadam, where
small quantity of WMM is to be executed. Manual mixing / layhing in inaccessible / remote locations and
in situations where use of machinery is not feasible can also be permitted. Were manual mixing / laying
is intended to be used, the same shall be done with the approval of the Engineer-in-charge.
16.63.3.5. Compaction:
After the mix has seen laid to the required thickness, grade and crossfall/camber the same
shall be uniformly compacted, to the full depth with suitable roller. If the thickness of single compacted
layer does not exceed 100 mm, a smooth wheel roller of 80 to 100 kN weight may be used. For a
compacted single layer upto 200 mm, the compaction shall be done with the help of vibratory roller

of minimum static weight of 80 to 100 kN with an arrangement for adjusting the frequency and
amplitude. An appropriate frequency and amplitude may be selected. The speed of the roller shall
not exceed 5 km/h.
In portions having unidirectional cross fall/superelevation, rolling shall commence from

the lower edge and progress gradually towards the upper edge. Thereafter, roller should
progress parallel to the centre line of the road, uniformly over-lapping each preceding track by at
least one-third width until the entire surface has been rolled. Alternate trips of the roller shall be
terminated in stops at least 1 m away from any preceding stop.
In portions in camber, rolling should begin at the edge with the roller running forward and backward
until the edges have been firmly compacted. The roller shall then progress gradually towards the
centre parallel to the centre line of the road uniformly overlapping each of the preceding track by at
least one-third width until the entire surface has been rolled.
Any displacement occurring as a result of reversing of the direction of a roller or from any other
cause shall be corrected at once as specified and/or removed and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall be thoroughly
compacted with mechanical tampers or a plate compactor. Skin patching of an area without scarifying
the surface to permit proper bonding of the added material shall not be permitted.
Rolling should not be done when the subgrade is soft or yielding or when it causes a wave-like
motion in the sub-base/base course or subgrade. If irregularities develop during rolling which exceed
12 mm when tested with a 3 metre straight edge, the surface should be loosened and premixed
material added or removed as required before rolling again so as to achieve a uniform surface
conforming to the desired grade and crossfall. In no case should the use of unmixed material be
permitted to make up the depressions.
Rolling shall be continued till the density achieved is at least 98 per cent of the maximum dry
density for the material as determined by the method outlined in IS: 2720 (Part-8)
After completion, the surface of any finished layer shall be well-closed, free from movement
under compaction equipment or any compaction planes, ridges, cracks and loose material. All loose,
segregated or otherwise defective areas shall be made good to the full thickness of the layer and
recompacted.
16.63.3.6. Setting and drying: After final compaction of wet mix macadam course, the road shall be
allowed to dry for 24 hours.
16.63.4. Opening to Traffic

No vehicular traffic of any kind should be allowed on the finished wet mix macadam surface till it
has dried and the wearing course laid.
16.63.5. Surface Evenness

All work perform shall confirm to the lines, grades, cross sections and dimensions shown on the
drawings or as directed by the Engineer-in-charge, subject to the permitted tolerances described
herein after.
16.63.5.1 Horizontal Alignment

Horizontal alignments shall be reckoned with respect to the centre line of the carriageway as
shown on the drawings. The edges of the carriage way as constructed shall be correct within a
tolerance of ± 10 mm there from. The corresponding tolerance for edges of the roadway and lower
layers of pavement shall be ± 25 mm.

16.63.5.2 Surface Levels
The levels of the Sub-base / base course as constructed, shall not vary from those calculated
with reference to the longitudinal and cross-profile of the road shown on the drawings or as directed
by the Engineer-in-charge beyond the tolerances mentioned as below:
TOLERANCES IN SURFACE LEVELS OF WMM
Sub-base
(a) Flexible pavement ± 10 mm
(b) Concrete pavement ± 06 mm
Base course flexible pavement

(a) Bituminous Base / Binder Course ± 06 mm
(b) Granular
(i) Machine laid ± 10 mm
(ii) Manually laid ± 15 mm
For checking compliance with the above requirement for sub-base / base courses, measurements of
the surface levels shall be taken on a grid of points placed at 6.25 m longitudinally and 3.5 m transversely.
The longitudinal profile shall be checked with a 3 metre long straight edge / moving straight-edge
as desired by the Engineer-in-charge at the middle of each traffic lane along a line parallel to the
centre line of the road.
16.63.6. Measurements
Wet Mix Macadam shall be measured as finished work in position in cubic metres. The length and
breadth shall be measured to the nearest centimetre. The depth of consolidated layer shall be
computed to nearest half centimetre by taking average of depths at the centre and at 30 cm from the
left and right edges at a cross section taken at 100 metre interval or less as decided by the Engineer-
in-Charge by making small pits. The consolidated cubical contents shall be calculated in cubic metres
16.63.7. Rates
The contract unit rate for Wet Mix Macadam shall be payment in full for carrying out the required
operations including all labour, tools, equipments machinery and incidentals to complete the work to
the specification as described above.
16.64 REFLECTIVE PAVEMENT MARKERS (RPM) OR ROAD STUDS

16.64.1 Scope
The work shall cover the providing and fixing of reflective pavement marker (RPM) or road stud,
a device which is bonded to or anchored within the road surface, for lane marking and delineation for
night-time visibility, as specified in the Contract.
16.64.2 Material
16.64.2.1 Plastic body of RPM/road stud shall be moulded from ASA (Acrylic Styrene Acrylonitrite) or
HIPS (Hi-impact Polystyrene) or Acrylonitrite Butadiene Styrene (ABS) or any other suitable material
approved by the Engineer. The markers shall support a load of 13.635 kg tested in accordance with
ASTM D 4280.
16.64.2.2 Reflective panels shall consist of number of lenses containing single or dual prismatic
cubes capable of providing total internal reflection of the light entering the lens face. Lenses shall be
moulded of merthyl methecrylate conforming to ASTM D 786 or equivalent.

16.64.3 Design
The slope or retro-reflecting surface shall preferably be 35 ± 5º to base and the area of each retro-
reflecting surface shall not be less than 13.0 sq.cm.
16.64.4 Optical Performance

16.64.4.1 Unidirectional and Bi-directional Studs.
Each reflector or combination of reflectors on each face of the stud shall have a Coefficient of Luminous
Intensity (C.I.L.), as specified in Table 16.48
TABLE NO 16.48
Minimum C.I.L. values for Road Studs
C.I.L. in mcd/lx
Entrance Angle Observation Angle
White Amber Red
0º U 5º L&R 0.3º 220 110 44
0º U 5º L&R 0.5º 120 60 24
16.64.5 Tests
16.64.5.1 Co-efficient of luminance intensity can be measured by procedure described in ASTM E 809 “Practice
for Measuring Photometric Characteristics” or as recommended in BS:873-Part 4 : 1973.
16.64.6 Fixing of Reflective Markers or Road Studs or Cats Eyes.

16.64.6.1 Requirements
The enveloping profile of the head of the stud shall be smooth and the studs shall not present any sharp
edges to traffic. The reflecting portions of the studs shall be free from crevices or ledges where dirt might
accumulate. Marker height shall not be less than 10 mm and shall not exceed 20 mm, and its width shall not
exceed 130 mm. The base of the marker shall be flat within 1.3 mm. If the bottom of the marker is configured,
the outermost faces of the configurations shall not deviate more than 1.3 mm from a flat surface. All road studs
shall be legibly marked with the name, trade mark or other means of identification of the manufacturer.
16.64.6.2 Placement
The reflective marker shall be fixed to the road surface using the adhesives and the procedure recommended
by the manufacturer. No nails shall be used to affix the marker so that they do not pose safety hazard on the
roads. Regardless of the type of adhesive used, the markers shall not be fixed if the pavement is not surface
dry and on new asphalt concrete surfacing until the surfacing has been opened to traffic for a period of not less
than 14 hours. The portions of the highway surface, to which the marker is to be bonded by the adhesive, shall
be free of dirt, curing compound, grease, oils, moisture, loose or unsound layers, paint and any other material
which would adversely affect the bond of the adhesive.
The adhesive shall be placed uniformly on the cleaned pavement surface or on the bottom of the of the
marker in a quantity sufficient to result in complete coverage of the area of contract of the marker with no voids
present and with a slight excess after the marker has been lightly pressed in place. For epoxy installations,
excess adhesive around the edge of the marker, excess adhesive on the pavement and adhesive on the
exposed surfaces of the markers shall be immediately removed.
16.64.6.3 Warranty and Durability

The contractor shall submit a two year warranty for satisfactory field performance including stipulated
retro-reflectance of the reflecting panel, to the Engineer-in-charge. In addition, a two year warranty for satisfactory
infield performance of the finished road marker shall also be given by the contractor who carries out the work
of fixing of reflective road markers. In case the markers are displaced, damaged, get worn out or lose their
reflectivity compared to stipulated standards, the contractor would be required to replace all such markers
within 15 days of the intimation from the Engineer-in-charge, at his own cost.

16.64.7 Measurement
The measurement of reflective road markers or road studs shall be made in numbers supplied
and fixed at site.
16.64.8 Rates
The rates include the cost of all the material, labour, tools and equipments required in all the
operation described above.
16.65 PRIME COAT OVER GRANULAR BASE

16.65.1 Scope
This work shall consist of the application of a single coat of low viscosity liquid bituminous material
to a porous granular surface preparatory to the superimposition of bituminous treatment or mix.
16.65.2 Materials
16.65.2.1 Primer:- The primer shall be cationic bitumen emulsion SS1 grade conforming to IS:8887 or
medium curing cutback bitumen conforming to IS:217 or as specified in the contract.
16.65.2.2 Quantity of SS1 grade bitumen emulsion for various types of granular surface shall be as given in
Table 16.49 or as specified in the item of contract.
Table 16.49
Quantity of Bitumen Emulsion for various types of Granular Surfaces
Type of Surface Rate of Spray (kg/sqm)

WMM/WBM 0.7-1.0
Stabilized soil bases/Crusher Run Macadam 0.9-1.2
16.65.2.3 Cutback for primer shall not be prepared at the site. Type and quantity of cutback bitumen
for various types of granular surface shall be as given in Table 16.50.
Table 16.50
Type and Quantity of Cutback Bitumen for various types of Granular Surface
Type of Surface Type of Cutback Rate of Spray (kg/sq.m)
WMM/WBM MC 30 0.6-0.9
Stabilized soil bases/Crusher Run MC 70 0.9-1.2

Macadam
16.65.2.4 The correct quantity of primer shall be decided by the Engineer-in-Charge and shall be
such that it can be absorbed by the surface without causing run-off of excessive primer and to
achieve desired penetration of about 8-10mm.
16.65.3.1 Equipment
The primer shall be applied by a self propelled or towed bitumen pressure sprayer equipped for
spraying the material uniformly at specified rates and temperatures. Hand spraying shall not be
allowed except in small areas, inaccessible to the distributor, or in narrow strips where primer shall be
sprayed with a pressure hand sprayer, or as directed by the Engineer-in-Charge.

16.65.3.2 Preparation of Road Surface
The granular surface to be primed shall be swept clean by power brooms or mechanical sweepers
and made free from dust. All loose material and other foreign material shall be removed completely.
If soil/moorum binder has been used in the WBM surface, part of this should be brushed and removed
to a depth of about 2 mm so as to achieve good penetration.
16.65.3.3 Application of Bituminous Primer

After preparation of the road surface the primer shall be sprayed uniformity at the specified rate
as per item of contract. The method for application of the primer will depend on the type of equipment
to be used, size of nozzles, pressure at the spray bar and speed of forward movement. The contractor
shall demonstrate at a spraying trial, that the equipment and method to be used is capable of producing
a uniform spray, within the tolerances specified.
No heating or dilution of SS1 bitumen emulsion and shall be permitted at site. Temperature of
cutback bitumen shall be high enough to permit the primer to be sprayed effectively though the jets
of the spray and to cover the surface uniformity.
16.65.3.4 Curing of Primer and Opening to Traffic

A primed surface shall be allowed to cure for at least 24 hours or such other higher period as is
found to be necessary to allow all the moisture/volatiles to evaporate before any subsequent surface
treatment or mix is laid. Any unabsorbed primer shall first be blotted with a light application of sand,
using the minimum quantity possible. A primed surface shall not be opened to traffic other than that
necessary to lay the next course.

Prime coat shall be measured in terms of surface area of application in square metres.
16.65.5 Rate
The contract unit rate for prime coat shall be payment in full for carrying out the required operations
i/c all equipments, labour and machinery as described above.

APPENDIX A
BITUMEN REGISTER
(Clause 16.24 to 16.31, 16.32, 16.33)
Name of Work:
Name of Contractor:
Receipts Issues
Quantity of Daily Junior
Date of Quantity Progressive Date of Bitumen Total Balance Contractor’s Engineer’s
receipt received total issue issued issue in hand initial initial
1 2 3 4 5 6 7 8 9
Daily Comparison of Issues with Requirements

Item of work for Approx. quantity Theoretical Assistant Executive
which issued of work done on requirement of Executive Engineer
each day bitumen for work Engineer/Assistant
done on each Engineer
day
10 11 12 13 14

APPENDIX B
DETERMINATION OF IN-SITU DENSITY OF ASPHALTIC CARPET OR

BITUMINOUS MACADAM BY SAND POURING DEVICE
The metallic tray of the field density unit is kept on a level spot of the surface and a hole 10 cm in
dia, is cut to the entire thickness of the carpet. All materials removed from the hole are carefully
collected and weighed.
A known weight of dry standard sand, passing 710 micron I.S. Sieve and retained on 355 micron
I.S. sieve, is taken in the sand pouring cylinder. The cylinder is kept directly over the hole and the
shutter of the cylinder is released without any jerk and closed when the hole is filled with the sand. The
quantity of the residual sand in the cylinder as well as the quantity filling the cone of the cylinder are
weighed.
The in-situ density of the carpet is calculated as follows:-
୅ǡୢ
Density:
ௐିሺௐଵାௐଶሻ
Where A = Weight of the materials removed from the carpet hole.

W = Initial weight of the sand taken in the cylinder.
W1 = Weight of the sand filling the cone of cylinder.
d = Bulk density, gm per cc of the sand.
W2 = Weight of sand remaining in the cylinder.

APPENDIX C
LIST OF MINIMUM EQUIPMENT TO BE PROVIDED IN THE FIELD

TESTING LABORATORY BY THE CONTRACTOR AT HIS OWN
COST.
Concrete Section
1. Sieve Analysis of stone ballast
(a) Sets of I.S. Sieves of sizes 63 mm, 45 mm, 22.4 mm, 11.2 mm, 5.60 mm. etc.
2. Sieve analysis of sand

(a) Sets of I.S. sieves of sizes 2.36 mm, 1.18 mm, 600 micron, 355 micron and 180 micron.
3. Silt content of sand

(a) Graduated glass cylinders 500 C.C. capacity.
4. Bulkage of sand
(a) Graduated glass cylinders 500 C.C. capacity.
5. Slump test.
(a) Slump cones.
(b) Slump rods 3/8" dia. 24" long bullet pointed.
(c) Steel plates 24” x 24”
(d) Steel scales.
6. For making beam specimens for flexural strength.

(a) Beam moulds.
(b) Tamping rods.
7. Testing flexural strength of concrete:-

(a) 100 ton capacity compressive strength testing i/c hand operated in two numbers with flexure
test attachment.
8. Other miscellaneous items.

(a) Physical balance with set of weights.
(b) Pan balances.
(c) Spring balances.
(d) Glass measuring jar.
(e) Beakers.
(f) Towels, glass plates etc.

APPENDIX D
GENERAL GUIDELINES ISSUED BY NDMC

I. Roads/Foot Paths/and Storm Water Drains.
A. RESIENTIAL
S.No Specifications applicable prior Specifications applicable Remarks

to 26.9.79 after 27.9.79 (Modified)
(1) (2) (3) (4)
1. 15 ft wide right of way service 4.577 tres (15ft) right of way
lanes: Metal width not less service lane:
than 8’-0” 4-1/2” soling 4-1/2” (i) Metalled width not less than 2.44
metal two coats of bitumen metres (8 ft.)
painting (ii) 0.1143 metres (4-1/2") thick stone
aggregate sub-base course of
W.B.M. as per IRC specifications.
(iii) 0.1143 metre (4-1/2") thick stone
aggregate base-course W.B.M. as
per IRC specifications.
(iv) 2 cm (3/4") thick pre-mix carpet with
seal coat of premixed stone dust.
(v) 0.2286 metre (9") wide brick-on-
edge edging on either side.
(vi) CC (M-150) channel 8 cm thick and
30 cm wide with gola of 8 cm radius
laid over a bed layer of 8 cm thick
1:5:10 c.c. top surface finished with
a floating coat of neat cement.
(vii)The space between brick edging
and c.c. channel on both sides shall
have brick on-edge flooring.
2. 20 ft. wide right of way service 6.098 metres (20 ft.) right of way
lanes: Metalled width 10 ft. service lane:
plus 9” brick-on-edge on (i) Metalled width 3.48 metres (10 ft.)
either side. 4-1/2” soling 4- (ii) 0.1143 metre (4-1/2") thick stone
1/2” metal ¾” bitumen carpet. aggregate sub-base course of
W.B.M. as per IRC specifications.
(iii) 0.1143 metre (4-1/2") thick stone
aggregate base-course of W.B.M.
as per IRC specifications.
(iv) 2 cm (3/4") thick pre-mix carpet with
seal coat of premixed stone.
(v) 0.2286 metre (9") wide brick on
edge edging on either side.C
(vi) C (M-150) channel 8cm thick and 30
cm wide with gola of 8 cm radius
laid over a bed layer of 8 cm thick
1:5:10 cement concrete top surface
finished with a floating coat of neat
cement.
(vii) The space between brick edging &
CC channel on both side brick on
edge flooring.
3. Roads with right of way 30 9.14 metre (30 ft.) right way roads:
feet: 12 ft. Metalled width plus (i) metres (12 ft.) mettalled width with
9" thick edging on either side. 0.2286 metre (9") wide brickon-
6" soling 6" metal (water edge-edging on either side

bound 3" thick each layer) (ii) 0.1016 metre (4") thick stone
3/4" carpet aggregate base-course of W.B.M.
as per IRC specifications.
(iii) 0.2032 metre (8") thick stone
as per IRC specifications (to be laid
in two layers).2
(iv) cm (3/4") thick pre mix carpet with
4. Service roads with right of 12.19 mtrs. (40 ft.) and less than 13.71 The change in
way 40 ft. 18 ft. metalled width mtrs. (45 ft.) right of way roads: metalled width is to
plus 9" thick edging on either (i) 7.32 m. (24 ft.) metalled width with adopt two lane
side. 6" soling 7-1/2" metal 0.2286 m (9") wide brick-on-edge width since 18 ft.
(water bound 4-1/2" & 3" thick edging on either side. width is not
separately) 1" carpet. (ii) 0.1524 m (6") stone aggregate sub- standard width.
base course of W.B.M. as per IRC
specifications.
(iii) 0.2032 m (7-1/2") stone aggregate
base-course of W.B.M. as per IRC
specifications (to be laid in two
layers)
(iv) 2.5 cm (1") thick pre-mix carpet with
5. Service roads with right of 13.71 mtrs. (45 ft.) and less than 18.29 The change in
way 60 ft. mtrs.(60 ft.) right of way road: metalled width
22 ft. metalled width plus 9" (i) 7.32 mtrs. (24 ft.) metalled with from 22 ft. to 24
brickon-edge on both sides. 6" 0.2284 m (9") wide brick-on-edge on ft. is to adopt
soling. 7-1/2" metal. 1-1/2" either side. standard two lane
thick asphaltic concrete. (ii) 0.1524 m (6") thick stone aggregate width.
sub-base course of W.B.M. as per
IRC specifications.
(iii) 0.2032 m (71/2”) thick stone
in two layers).
(iv) 5 cm (2”) thick Bituminous
Macadam (B.M.) with seal coat of
premixed stone dust.
6. Roads with right of way above 18.29 mtrs. (60 ft.) and less than 24.38 The change in
60 ft. and upto 79 ft. 22 ft. mtrs. (80 ft.) right of way road metalled width
metalled width 9" brick-on- (i) 7.32 mtrs. (24 ft.) metalled with from 22 ft. to 24 ft.
edge on either side. 9" soling 0.2286 mtrs. (9”) wide brick-on-edge is to adopt
7-1/2" metal (W.B.M. 4-1/2" & edging. standard two lane
3" thick separately). 1-1/2" (ii) 0.1524 m (6”) thick stone aggregate width.
thick asphaltic concrete sub-base of W.B.M. as per IRC
specifications.
(iii) 0.2667 m (10-1/2”) thick stone
in three layers).
(iv) 5 cm (2”) thick Bituminous
Macadam (BM) with seal coat of
7. Roads with right of way 80 ft. 24.38 mtrs. (80 ft.) and above right of The change in
and above 9" soling. way road. metal width is to
Metalled width 24 ft. soling 9" adopt standard X
7- 1/2" metal. 1" carpet. (i) 14.64 mtrs. (48 ft.) metalled width. section for 80 ft.

(ii) 0.1524 m (6”) thick stone aggregate wide roads. Such
sub-base course of W.B.M. as per roads normally
IRC specifications. carry heavy
(iii) 0.2667 m (10-1/2”) thick stone amount of traffic
aggregate base-course of W.B.M. which needs a
as per IRC specifications (to be laid metalled width of
in three layers). 48 ft. for easy flow
(iv) 5 cms. (2”) thick Bituminous of traffic.
Macadam (BM) with seal coat of
(v) 3.048 mtrs. (10 ft.) wide raised foot
path on both sides of the
carriageway as per specifications
given hereinafter.
8. Service lanes/ walkways Service lanes/walkways having right of
having right of way less than way less than 4.57 mtrs.(15 ft.)
15 ft. Nil 0.1143 mtrs. (4-1/2”) thick cement
concrete (M-150) over 0.1143 (4-1/2”)
dry brick ballast in complete width with
c.c. (M-150) channel 8 cms. thick and
30 cm wide with gola of 8 cm radius laid
over a bed layer of 8 cms. Thick 1:5:10
cement concrete top surface finished
with floating coat of neat cement.
Notes :
(a) Roads with right of way 80 ft. and above passing through residential colony should have raised
foot paths on either sides.
(b) Where it is necessary for practical requirements to do the road work in two stages then it is
advisable to do a coat of bitumen painting after leaving the first layer of water bound macadam.
(c) Brick-edging 9" wide shall be provided beyond the metalled width of roads in item (2) to (5)
above.
(d) Brick pitched drains with adequate discharging capacity shall be provided on both sides of the
road.
(e) Where raised footpaths are not provided, berms shall be properly dressed to slope towards the
side drains.
Foot-Paths and Storm Water Drains for Roads in
Residential and Industrial Areas
1 2 3 4
1. 10 ft. wide foot- 3.048 mtrs. (10 ft.) wide foot-path
path (i) 0.076 m (3") thick dry brick ballast.
(ii) 0.076 m (3") thick cement concrete M-150
pavement with or without chequered tiles
embedded in cement concrete.
(iii) Cement concrete (M-150) kerbstones of size
0.3048 m x 0.203 m (12" x 8")
(iv) 0.2286 m x 0.3048 m brick toe wall on the other
end of foot-path.
(v) 0.3048 m (1 foot) wide channel with C.C. (M-150)
75 mm thick over 75 mm bed concrete 1:5:10
finished with a floating coat of neat cement.
(vi) NP class R.C.C. pipes 150 mm dia with collars
jointed with cement mortar 1:2 (1 cement: 2 fine
sand) for cross drainage with gully chambers of
size 50 x 45 x 65 cms. with M.S. grating of size
500 x 450 mm

Notes:
1. Brick pitched drains with adequate designed discharge capacity shall be provided on both sides
of the roads above 20 ft. right of way (For cross section of different R.O. roads, showing the
carriage width, arrangement of footpaths, storm water drains, water supply mains, sewer lines
and also of trees.
2. Where raised foot-paths are not provided, berms shall be properly dressed to slope toward the
side drains.
3. The work shall be carried out as per prevailing CPWD/IRC specifications.
4. Crust thicknesses mentioned in the above specifications mean compact thicknesses.
5. Brick edging wherever mentioned in the above specifications shall be 0.1143 m (4-1/2") deep.
6. For any road having right of way other than mentioned in the specifications, the standard of the
next higher R.O.W. will be applicable.
S.No Specifications Specification applicable after 27.9.79 (Modified)

applicable prior to
26.9.79
1 2 3
1 NIL ……………….. (1) Roads/Service lanes having R/W less than 6.10 metres (20 ft.).
(i) Minimum length of the culvert shall be the entire width of R/W.
2 NIL ……………….. (2) Roads having R/W 6.10 metres (20 ft.).
(i) Minimum length of the culvert shall be 4.57 metres (15 ft.).
3 NIL ……………….. (3) Roads having R/W 9.14 metres (30 ft.).
(i) Minimum length of the culvert shall be 6.10 metres (20 ft).
4 NIL ……………….. (4) Roads having R/W 12.19 m (40 ft.).
5 NIL ……………….. (5) Roads having R/W 13.72 m (45 ft.).
6 NIL ……………….. (6) Roads having R/W 18.29 m (60 ft.) and less than 24.38 m (80 ft.).
7 NIL ……………….. (7) Roads having R/W 24.38 m (80 ft.) and above.
(i) Minimum length of the culvert shall be metalled width + width of foot-
paths.
Notes :
(i) Slab of the culvert shall be of R.C. C. M-150 with suitable reinforcement.
(ii) Minimum thickness of R.C.C. slab shall be 0.1524 m (6") for culverts in residential areas and
0.2286 m (9") for culverts in industrial areas.
(iii) Maximum span of the culverts slab shall be 1.165 m (4 ft.) C/C.
(iv) 0.9144 m high parapet of brick masonry and plastered with cement mortar 1:4 (1 cement: 4
coarse sand) finished with a floating coat of neat cement will be constructed on both sides of
culvert.

PROVISION FOR LATERAL CONFINEMENT OF AGGREGATES
Sub Head : Road Work
Clause: 16.7.5
Drawing not to Scale

Fig. 16.1 : Provision for Lateral Confinement of Aggregates

R.C.C. NAME BOARD WITHOUT POST

Fig. 16.2 : R.C.C. Name Board without Post

SIGN/NAME BOARD
Sub
ub Head : Road Work

Red Reflectors
Fig. 16.3 : Sign/Name Board

BOUNDARY STONE

Clause : 16.20 & 16.21

All Dimensions are in mm
Fig. 16.4 : Boundary Stone

STANDARD NUMERALS
Clause : 16.19
Note : To determine the proper spacing between numerals obtain the code number from Table III and enter Table II for
that Code Number to Desired Numeral Height. Spacing is measured horizontally from the extreme right edge of the
preceding numeral to the extreme left of the following numeral. For Dimensions of numerals of different heights see
Table I.
Drawing not to scale

Fig. 16.5 : Standard Numerals

STANDARD LETTERS

Clause : 16.19
Note : To determine the proper spacing between letters obtain the code number from Table III and enter Table II for that Code
Number to Desired Height. Spacing is measured horizontally from the extreme right edge of the preceding Letter to the
extreme left edge of the following letter. For Dimensions of letters of different heights, see Table I.
Drawing not to scale
Fig. 16.6 : Standard Letters

KILOMETRE STONES TYPE DESIGN
Clause : 16.22
DRAWING NOT TO SCALE

ALL DIMENSIONS ARE IN MM.
RCC THICKNESS ‘T’ SHALL BE 250
OTHER MATERIAL
THICKNESS MAY VARY.
Fig. 16.7 : Kilometre Stones Type Design

KILOMETRE STONE LOCATION (FOR HIGHWAYS)
Clause : 16.22

ALL DIMENSIONS ARE IN MM
Fig. 16.7A : Kilometre Stones Location (For Highways)

INFORMATORY SIGN BOARD
Clause : 16.49

Fig. 16.8 : Informatory Sign Board

BARBED WIRE FENCING (WITH R.C.C. POST)
Clause : 16.16
1. In case of end post one strut shall be omitted.

2. Drawing not to Scale
3. All dimensions are in mm.
Fig. 16.9 : Barbed Wire Fencing

FENCING WITH R.C.C. POST RAILS, PALES

Clause : 16.18.6

Fig. 16.10 : Fencing with R.C.C. Post Rails, Pales

LOCATION OF INFORMATORY SIGN BOARDS

Clause : 16.49
Fig. 16.11 : Location of Informatory Sign Boards

KERB & CHANNEL STONES
Clause : 16.1.20

Fig. 16.12 : Kerb & Channel Stones

BROAD DETAILS OF COOKER FOR BITUMEN MASTIC IN WEARING
COURSES
Clause : 16.33.3
Drawing not to Scale.

All dimensions are in mm.
Fig. 16.13 : Broad Details of Cooker for Bitumen Mastic in Wearing courses

SUB HEAD : 17.0
SANITARY INSTALLATIONS
877
CONTENTS
List of Bureau of Indian Standards (BIS) Codes 883
17.1 Appliances and Fittings 888
17.1.1 Flushing Cisterns 888
17.1.2 Draining Board 893
17.1.3 Foot Rests 894
17.1.4 Glass Shelf/ PVC Shelf 894
17.1.5 Mirror 894
17.1.6 M S Stays and Clamps 894
17.1.7 Pillar Taps 894
17.1.8 Sand Cast Iron or Centrifugally Cast (Spun) Iron Pipes 895
and Fittings
17.1.8A Hubless Centrifugally Cast (Spun) Iron pipes and fittings 896
17.1.9 Plastic Seat and Covers for Water Closet 897
17.1.10 Sinks 898
17.1.11 Towel Rail 898
17.1.12 Toilet Paper Holder 898
17.1.13 Urinals 898
17.1.14 Wash Basins 899
17.1.15 Waste Fittings for Wash Basins and Sinks 899
17.1.16 Water Closet 900
17.2 General Requirements for Installation of W. C. Pan 900
17.3 Installation of Draining Board 901
17.4 Installation of Flushing Cistern 902
879 SUB HEAD 17.0 : SANITARY INSTALLATIONS

17.5 Installation of Mirror 902
17.6 Fixing and Jointing of Pipes and Fittings 902
17.7 Installation of Seat and Cover to Water Closet 905
17.8 Installation of Sink 905
17.9 Installation of Urinal - Lipped, Half Stall (Single or Range) 905
17.10 Installation of Stall Urinal (Single of Range) 906
17.11 Installation of Wash Basin 907
17.12 Installation of Squatting Pan 907
17.13 Installation of Water Closet 908
17.14 Installation of Foot Rests 908
17.15 Installation of Squatting Plate (Single or Range) 908
17.16 Installation of Towel Rail 909
17.17 Installation of Stainless Steel Sink 909
17.18 Cutting Chase in Masonry Wall 910
17.19 Painting Synthetic Enamel Paint on SCI/Centrifugally 910

Cast (Spun) Iron Soil, Waste and Vent Pipes
17.20 Repainting SCI/Centrifugally Cast (Spun) Iron Soil, Waste 911

and Vent Pipe
17.21 Installation of Wall Mounting Water Closet (WC) 911
17.22 Installation of Floor Mounted Single Piece Water 912

Closet (WC)
Appendix A Standard Weights and Thickness of C.I. Pipes 913
Appendix B Drawing and dimensions for stainless steel 914

shielded coupling
Fig. 17.1 Pipe Systems and Parts 916
Fig. 17.2 Pipe Systems and Parts 916
Fig. 17.3 Flushing Cisterns 917

Fig. 17.4 Foot Rest 918
Fig. 17.5 M.S. Stays and Clamp 919
Fig. 17.6 Plastic Seat and Cover 920
Fig. 17.7 Kitchen & Laboratory Sinks 921
Fig. 17.8 Waste Fittings for W.B. & Sinks 922
Fig. 17.9 Urinal Bowl Type 923
Fig. 17.10 Urinal Bowl Type (Corner Wall Type) 924
Fig. 17.11 Urinal - Half Stall 925
Fig. 17.12 Urinal Squatting Plate 926
Fig. 17.13 Spreader for Urinal 927
Fig. 17.14 Wash Basins 928
Fig. 17.15 Fixing Arrangement of Wash Basins 929
Fig. 17.16 Typical Vertical Section of Wash Basins (Waste Pipe 930
Open to View)
Fig. 17.17 Typical Vertical Section of Wash Basin (Waste Pipe 931
Concealed from View)
Fig. 17.18 Angle Back Wash Basin (Pattern-2) 932
Fig. 17.19 Long Pattern Squatting Pan (Type-I) 933
Fig. 17.20 Orissa Pattern Squatting Pan 934
Fig. 17.21 Integrated Squatting Pan 935
Fig. 17.22 Pattern 1 and Pattern 2-Water Closets 936
Fig. 17.23 Pattern 3-Water Closet with Horizontal P-Trap 937
Fig. 17.24 Typical coupling joint-installation 938
Fig.17.25 Typical illustration of Wall Mounted Water Closet with 939

Concealed Outlet (Pattern 1)
Fig.17.26 Typical illustration of Water Closet with fixing arrangement 940

on top of Bracket (pattern 2)

LIST OF BUREAU OF INDIAN STANDARDS (BIS) CODES

1. IS 771 (Pt.1) Specification for glazed fire clay sanitary appliances: Part 1: General
requirements.
2. IS 771 (Pt.-2) Specification for glazed fire clay sanitary appliances: Part 2: Specific
requirements of kitchen and laboratory sink.
3. IS 772 Specific action for general requirements for enameled cast iron
sanitary appliances.
4. IS 774 Flushing cisterns for water closets and urinals (Other than plastic
cistern)-Specifications.
5. IS 1300 Phenolic moulding materials.- Specifications
6. IS 13983 Providing and fixing stainless steel sink
7. IS 1570 (Part-5) Schedule for Wrought steel (Stainless Steel and heat resisting
steels)
8. IS 1703 Water fittings- copper alloy float valves (horizontal plunger type) -
Specification.
9. IS 1729 Cast iron /Ductile Iron Drainage Pipes and pipe fittings for Over
ground non-pressure pipe line Socket and Spigot Series.
10. IS 1795 Specification for pillar taps for water supply purposes.
11. IS 1865 Iron casting with spheroidal or nodular graphite
12. IS 2267 Polystyrene moulding and extrusion materials - Specifications
13. IS 2326 Specification for Automatic Flushing Cisterns for Urinals (Other than
plastic cisterns)
14. IS 2548 (Part-1) Plastic seats and covers for water closets Part 1: Thermo set seats
and covers - Specifications
15. IS 2548 (Part-2) Plastic seats and covers for water closets Part 2: Thermoplastic
seats and covers.- Specifications
16. IS 2556 Vitreous sanitary appliances (vitreous china) -Specifications
17. IS 2556 (Part-1) Part-1: General requirements.
18. IS 2556 (Part-2) Part-2: Specific requirements of wash-down water closets.
19. IS 2556 (Part-3) Part-3: Specific squatting pans.
20. IS 2556 (Part-4) Part-4: Specific requirements of wash basins.
21. IS 2556 (Part-5) Part-5: Specific requirements of laboratory sinks.
22. IS 2556 (Part-6) Part-6: Specific requirements of Urinals & Partition plates
23. IS 2556 (Part-7) Part-7: Specific requirements of accessories for sanitary appliances
24. IS 2556 (Part -14) Part-14: Specific requirements of integrated squatting pans.

25. IS 2556 (Part -15) Part-15: Specific requirements of universal water closets.
26. IS 2556 (Part -16) Part-16: Specific requirements of wash down wall mounted water
closets
27. IS 2963 Specification for Copper alloy waste fittings for wash basins and
sinks.
28. IS 3076 Specification for low density polyethylene pipes for potable water
supplies.
29. IS 3389 Urea formaldehyde moulding materials. - Specifications
30. IS 3989 Specification for centrifugally cast (spun) iron spigot and socket
soil, waste and ventilating pipes fittings and accessories.
31. IS 4827 Specification for electroplated coating of nickel and chromium on
copper and copper alloys.
32. IS 4984 Specification for high density polyethylene pipes for potable water
supplies.
33. IS 4985 Unplasticised P.V.C. pipes for potable water supply - Specifications.
34. IS 7231 Plastic flushing cisterns for water closets and urinals -
Specifications.
35. IS 13983 Stainless steel sinks for domestic purposes -Specifications.
36. IS 15905 Centrifugally Cast Iron Hubless pipes & fittings

17.0 SANITARY INSTALLATIONS
17.0 TERMINOLOGY
Antisiphon Pipe (Fig. 17.1)

A ventilating pipe connected to or close to the outlet side of a trap seal.
Automatic Flushing Cistern (Fig. 17.3)

A flushing cistern arranged to discharge its content by siphonage at regular intervals, determined
by the rate at which water is fed into the cistern.
Ball Cock (Fig. 17.3)

A faucet opened or closed by the fall or rise of a ball floating in the surface of water.
Ball Valve (Fig. 17.3)

A simple non return valve consisting of a ball resting on a cylindrical seat within a fluid passageway.
Bell Mouth (Fig. 17.3)

An expanded rounded entrance to a pipe or orifice.
Bend
Length of pipe bent or cast into an angle shape.
Bib Tap
A tap with a horizontal inlet and nozzle bent to discharge in a downward direction.
Blister
A raised portion of the surface protruding not more than one millimeter above the surface and not
greater than 3 mm in its greatest dimension.
Box Union
A device for joining two threaded pipes.
Branch (Fig. 17.1)

(a) A special form of vitrified sewer and cast iron pipe used for making connections to a sewer
or water main. The various types are called T, Y, T-Y, double Y, and V branches, according
to their respective shapes.
(b) Any part of piping system other than a main.
Caulking
(a) The process of driving, pouring or forcing lead, oakum, plastic or other material into a joint
to make it leak proof.
(b) The material used in the caulking process.
Caulked Joint
A spigot and socket joint in which the jointing material is compacted by means of caulking tool
and hammer.

Chase
A continuous recess in wall, floor or ceiling for the purpose of holding pipes and conduits.
Cistern (Fig. 17.3)

A fixed container for water in which the water is at atmospheric pressure. The water is usually
supplied through a ball valve.
Collar
A pipe-fitting in the form of sleeve for jointing the spigot ends of two pipes in the same alignment.
Cowl (Fig. 17.1)

A hood on the top of a vent pipe or soil stack.
Craze or Crazing
Fine cracks in the glaze.
Cross
A pipe fitting used for connecting four pipes at right angles.
Fittings
Coupling, flange, branch, bend, tee, elbow, union, waste with plug, P or S trap with vent, ferrule,
stop tap, bib tap, pillar tap, globe tap, ball valve, cistern, storage tank, baths, water closets, boiler
geyser, pumping set with motor and accessories, metre, hydrant valve and any other article used in
connection with water supply, drainage and sanitation.
Float Valve (Fig. 17.3)

A valve in which the closure to an opening such as a plug or gate, is actuated by a float to control
the flow in to a tank.
Flush Bend
A bend located at the bottom of low level flushing cistern for the purpose of flushing pedestal type
water closet and similar fixture.
Flushing Cistern (Fig. 17.3)

A cistern provided with a device for rapidly discharging the contained water and used in connection
with a sanitary appliance for the purpose of cleaning the appliance and carrying away its contents
into a drain.
Gasket
A piece of compressible material used to make a joint between two flat surfaces.
Oakum
Hemp or old hemp rope soaked in oil to make it water proof.
One Pipe System (Fig. 17.1)

In this a single soil waste pipe conveys both soil and waste directly to the building drain.
Pinhole
A hole in the body, less than 1.5 mm, in its maximum dimension.
Reducer
A pipe-fitting with inside threads larger at one end than at the other. All such fittings having more
than one size are reducers because of the custom of stating the larger size first.

Single Stack System (Fig. 17.1)
This is the name given to a simplified one pipe system wherein all ventilation pipes are omitted.
The stack itself is made to cater (or provide) for all the vent requirements by restricting the flow into
the stack to certain predetermined limits.
Sink (Fig. 17.7)

A shallow fixture, ordinarily with a flat bottom, that is usually used in kitchen or in connection with
the preparation of food, laboratory purposes and for certain industrial processes.
Socket
The female part of spigot and socket joint.
Soil Pipe
A pipe which conveys to drain the discharge from a water closet or urinals. In ‘One pipe’ and
‘single stack’ system the soil pipe also conveys to a drain the discharges from bath, wash basins,
sinks and similar appliances.
Speck
Area of the finished surface with contrasting colour less than one millimeter maximum dimension.
Spigot
The male part of a spigot and socket joint.
Spigot and Socket Joint

Joint in which the end of the one pipe enters the enlarged end of the next pipe.
Stack
A main vertical discharge or ventilating pipe.
Trap
A fitting or device so designed and constructed as to provide, when properly vented, a liquid seal
which will prevent the back passage of air without materially affecting the flow of sewage or waste
water through it.
Two Pipe System (Fig. 17.1)

In this, the soil pipe conveys discharges from water closets, urinals, and similar soil appliances
directly to the drainage system and the waste pipe conveys waste from ablutionary and culinary
appliances to the drainage system directly or through a trapped gully where desired.
Union
A pipe fitting used for joining the ends of two pipes neither of which can be turned.
Valve
A device used for controlling the flow of liquid in a line of pipe.
Ventilating Pipe (Vent Pipe)

The pipe which provides a safe outlet into the atmosphere for the foul gases in the drain or
sewer.
Warpage
Distortion of original shape during manufacturing process.

Water Seal
The depth of water which should be removed from a fully charged trap before air can pass
through the trap.
Waste Pipe
A pipe used to convey liquid waste not containing human excreta.
Waste Stack
A vertical pipe used to convey liquid waste not containing human excreta.
17.1 APPLIANCES AND FITTINGS

17.1.0 All vitreous sanitary appliances (Vitreous China) shall conform to IS 2556 (Part-I) general
requirements.
17.1.1 Flushing Cisterns (Fig. 17.3)

The flushing cisterns shall be automatic or manually operated high level or low level as specified,
for water closets and urinals. A high level cistern is intended to operate with minimum height of 125
cm and a low level cistern with a maximum height of 30 cm between the top of the pan and the under
side of the cistern.
Cisterns shall be of following type (i) Vitreous China (IS 774) for Flushing type (ii) Automatic
Flushing Cistern (IS 2326) and (iii) Plastic cisterns (IS 7231).
17.1.1.1 Vitreous Chine Cisterns : The thickness of the body including cover shall be not less than
6 mm for vitreous China cisterns. The outlet of each syphon or stand pipe shall be securely connected
to the cistern by means of lock nut. The cistern shall be free from manufacturing faults and other
defects affecting their utility. All working parts shall be designed to operate smoothly and efficiently.
Cistern shall be mosquito proof. A cistern shall be considered mosquito proof only if there is no
clearance any where which would permit a 1.6 mm wire to pass through in the permanent position of
the cistern i.e. in the flushing position or filling position.
The breadth of a low level cistern, from front to back shall be such that the cover or seat, or both,
of water closet pan shall come to rest in a stable position when raised.
The cistern shall be supported on two cast iron brackets of size as approved by the Engineer-
in-Charge and embedded in cement concrete 1:2:4 block 100 x 75 x 150 mm. These shall be
properly protected by suitable impervious paint. Alternatively the cisterns shall have two holes
in the back side above the overflow level for screwing into the wall, supplemented by two cast
iron wall supports. A 5 litres cistern, however, may be supported by larger brackets cast on the
body of the cistern.
The cistern shall have a removable cover which shall fit closely on it and be secured against
displacement. In designs where the operating mechanism is attached to the cover this may be made
in two sections, but the section supporting the mechanism shall be securely bolted or screwed to the
body. The outlet fitting of each cistern shall be securely connected to the cistern. The nominal
internal diameter of cistern outlet shall be not less than 38 ± 1mm for low level cisterns respectively.
The length of the outlet of the cistern shall be 37 ± 2 mm.

Ball valve shall be of screwed type 15 mm in diameter and shall conform to IS 1703. The float
shall be made of polyethylene as specified in IS 9762. (The design shall permit the cistern to fill in
rapidly and close effectively when the level of water reaches the working water level.)
In the case of manually operated cisterns the siphonic action of the flushing cistern shall be
capable of being rapidly brought into action by the operating lever, but shall not self siphon or leak.
When tested according to IS 774 the discharge rate shall be 10 ± 0.5 litre in 6 seconds and 5 ± 0.5
litre in 3 seconds for cisterns of capacities 10 litre and 5 litre respectively. The cisterns shall be so
designed that there is not appreciable variation in the force of flush during the discharge of the
required quantity of water. The cistern shall have a discharge capacity of 5 & 10 litres as specified.
When required to give a full flush, they shall respectively discharge 5 litres and 10 litres with variation
of ± 0.5 litres.
The flush pipe shall be of (a) medium quality galvanised iron having internal diameter of 38
± 1 mm for low level cistern. The flush pipe shall be of suitable length with bends etc. as
required for fixing it with front or back inlet W.C. Pan. (b) Polyethylene pipes low density
conforming to IS 3076 or high density (c) Unplasticised PVC pipes. For high density polyethylene
and unplasticised PVC pipes, the outside diameter of the pipes shall be 40 mm. When PVC
plumbing pipes are used the outside diameter of the pipe shall be 40 mm for high level cisterns
and 50 mm for low level cisterns.
In case of low level cistern the flush pipe shall be a vertical pipe 30 cm long and having a
nominal internal dia 38 ± 1 mm (except plastic flush pipes).
Over Flow Pipe

(a) GI overflow pipe shall be of not less than 20 mm nominal bore and shall incorporate a non-
corrodible mosquito proof brass cover having 1.25 mm dia perforation, screwed in a manner
which will permit it to be readily cleaned or renewed when necessary. No provision shall be
made whereby the overflow from the cistern shall discharge directly into the water closet or
soil pipe without being detected.
The invert of the overflow pipe in the case of high level and low level cisterns shall be 19 mm
minimum above the working water level. In case of overflow due to any reason water should
drain out through the over flow pipe and not through the siphon pipe.
(b) The plastic overflow pipes shall be manufactured from high density polyethylene conforming
to IS 4984 or unplasticised P.V.C. conforming to IS 4985.
Inlet and Overflow Holes: The cistern shall be provided with inlet and overflow holes, situated one
at each end which shall be capable of accommodating an overflow pipe of not less than 20 mm
nominal bore and a 15 mm size ball valve. The holes shall be cleanly cast or drilled and the adjacent
surfaces shall be smooth.
17.1.1.2 PVC Cisterns : Plastic flushing cisterns for WC and Urinals shall be as per IS 7231.
The materials for manufacturing various components of the flushing cisterns shall conform to
the requirements given in Table 17.1 below:

TABLE 17.1
Materials for Various Components of Flushing Cisterns
Sl. No. Component(s) Material Conforming to
(1) (2) (3) (4)
1. Cisterns High density polyethylene (HDPE) IS 7328
Or
Polystryene, high impact IS 2267
Or
1) -
Polypropylene
Or -
Acrylonitrile-butadiene-styrene (ABS)
Or -
Glass Fibre reinforced plastic (GRP)
2. Flush pipe Steel tube, seamless or welded, medium or light,

completely protected inside and outside by hot-dip
galvanizing, electroplating or vitreous enamelling
Or
Lead pipe IS 1239 ((Part 1)
Or
IS 404 (Part 1)
Copper alloy tube
Or IS 407
High density polyethylene pipe
Or IS 2501
Unplasticised PVC plumbing pipe
3. Cover Same material as that of the body

4. Chain Hot-dip galvanized steel wires -
Or
Inter-locked non-ferrous metal
Or
Any other corrosion resistant material
5. Overflow pipe High density polyethylene IS 4984
Or IS 4985
Unplasticised PVC
Or
Any other corrosion-resistant material
6. Siphon/Valve High density polyethylene IS 7328
Or
Polystyrene, high impact IS 2267
Or
Polypropylene -
Or
Acrylonitrile- butadiene-styrene -
Or
Glass fibre reinforced plastic (GRP)
Operating Non-ferrous metal or any other corrosion resistant
7. Mechanism/ Lever material -
8. Float valve Water fittings-Copper Alloy Float Valves (Horizontal IS 1703
Plunger type)
Plastic equilibrium float valve for cold water IS 12234
services
Diaphragm type (plastic body) float operated valves for IS 13049
cold water services
9. Polyethylene float As specified in IS 9762

for float valve
10. Coupling nut and Non-ferrous metal,
lock-nut Or
Hot-dip galvanised steel
Or
Hot-dip galvanised malleable iron
Or

(1) Talc as filler, if used shall not exceed 20%
Note: Where the requirements for the material of any component or the relevant Indian
Standard designation for any material are not specified, these shall be as directed by the
Engineer-in-Charge.
The thickness of the body including cover at any point shall not be less than 2 mm for GRP, and
not less than 3 mm for other plastic materials. The cistern shall be free from manufacturing faults and
other defects affecting its utility. All working parts shall be designed so as to operate smoothly and
efficiently. The cistern shall be mosquito-proof. It shall be deemed to be mosquito proof only when
there is no clearance anywhere in it which would permit a 1.6 mm diameter wire to pass through. The
outlet of each siphon or stand pipe or flush valve shall be securely connected to the cistern by
means of a lock nut. In the case of plastic siphon, it shall be provided with suitable means of ensuring
and maintaining watertight and airtight joint to the cistern.
The cistern shall be provided with a removable cover which shall fit closely and shall be secured
against displacement. In designs, where the operating mechanism is attached to the cover, the cover
may be made in two sections, the section supporting the mechanism being securely fixed or booked
to the body.
The flush pipe (except plastic flush pipe) shall have an internal diameter of 32 + 1 mm for high
level cistern and 38 + 1 mm for low level cistern. The steel flush pipe shall be not less than 1 mm thick
whereas the lead flush pipe shall have a minimum thickness of 3.5 mm. For high density polyethylene
pipes, the outside diameter of the pipes shall be 40 mm. For unplasticised PVC plumbing pipes the
outside diameter of the pipe shall be 40 mm for high level cisterns, and 50 mm for low level cisterns.
In the case of high level flushing cisterns, a pipe clip fitted with a rubber buffer shall be fixed to the
flush pipe to prevent damage either to the pipe or to the seat when the seat is raised. No flush pipe
is required for coupled cisterns.
Note: The minimum thickness specified is for normal conditions of service. Where highly corrosive
atmospheres are expected, greater thicknesses are required to be provided as per
nomenclature of the item.
Flush Pipe Connection to Cistern

The flush pipe shall be securely connected to cistern outlet and made airtight by means of a
coupling nut. The nuts made of injection-molded HDPE/Polyacetal may be used only if the end pipe
is also made of plastic. The nominal internal diameter of the cistern outset shall be not less than 32
mm and 38 mm for high-level and low-level cisterns respectively.
The screw threads for connection to the flush pipe shall not be less than size 1½ of IS 2643
(Part 3). In the case of polyethylene and unplasticised PVC flush pipes, the upper end of the flush
pipe shall be provided with suitable means of ensuring and maintaining a watertight and airtight joint
to the flushing cistern. When ordered for use with a flush pipe, the outlet connection may be supplied
with coupling nut made of copper based alloy or other non-corrodible material and a plain tail piece
having a minimum length of 60 mm. The centre of the outlet hole shall be generally central to the
length of the cistern. The length of the outlet shall be 37±2 mm in case of interchangeable siphon;
however, where integral siphon is provided, the outlet length shall be 20±2 mm.
Note: The length of the cistern outlet shall be the dimension from the bottom surface of the cistern
to the end of the outlet after the cistern with siphon/stand pipe has been duly fitted with all
washers, lock-nuts, etc.

Inlet and Overflow Holes
The cistern shall be provided with inlet and overflow holes, situated one at each end, which shall
be capable of accommodating overflow pipe of not less than 20 mm nominal bore and a 15 mm size
float valve. The holes shall be cleanly moulded or drilled and the adjacent surfaces shall be smooth.
Float Valve
The float valve shall be 15 mm nominal size and shall conform to IS 1703 or IS 12234 or IS 13049.
Operating Mechanism Lever

The operating mechanism/lever shall not project beyond the side of the cistern for a distance
greater than 350 mm measured from the centre of the cistern to the end of the lever arm. The lever
arm shall be provided with a suitable hole near the end through which a split ring or S-hook can be
inserted. A string (chain) shall be attached to the ring or hook. When S-hook is employed, it shall be
effectively closed after assembly to prevent accidental disconnection.
In the case of low- level cisterns, where the mechanism is handle operated, the handle, whether
situated on the front or at the end of the cistern, shall be within the projection limit. Particular attention
shall be given to the case of operation of the handle.
String (Chain)
The string (chain) shall be of such strength as to sustain a dead load of 500 N without any
apparent or permanent deformation.
The string (chain) shall terminate in a suitable handle or pull made of a moulding in any heat-
resisting and non-absorbent plastic or any other equally suitable material. The finish shall be smooth
and all burrs which are liable to cause injury to the hand when gripped shall be removed.
Overflow Pipe
The overflow pipe shall be of not less than 20 mm nominal bore and shall incorporate a non-
corrodible mosquito-proof device secured in a manner which will permit it to be readily cleaned or
renewed when necessary. No provision shall be made whereby the overflow from the cistern shall
discharge directly into the water-closet or soil pipe without being detected.
The invert of the overflow pipe in the case of high-level and low level cisterns and the top edge of
the overflow pipe in the case of coupled cistern shall be 19 mm (Min) above the working water level.
In case of overflow due to any reason, water should drain out through the overflow pipe and not
through the siphon pipe.
Finish
The surface of the cistern including cover shall be free from blisters and delamination, and
reasonably free from flow lines, streaking or colour variations. The cistern and cover shall be opaque
to light.
Operational and Performance Requirements

Flushing Arrangement
The cistern under working conditions and with the float valve in closed position shall operate on
a single operation of the operating mechanism/lever without calling for a sudden jerk in pulling. If a
valve is used instead of siphon for flushing purposes, the valve shall be completely leak proof.
Working Water Level

The working water-level shall be a minimum of 6.5 cm. below the effective top edge of the cistern
and shall be legibly and permanently marked on the inside of the cistern. Effective top edge shall be
taken on edge after top of the body without considering bead.

Freedom from Self Siphonage
The siphonic system shall be capable of being rapidly brought into action when the water is at the
working water level, but shall not self siphon or leak into the flush pipe when the water is up to 1 cm
above the invert of the overflow pipe.
Reduced Water Level

The discharge shall operate satisfactorily when the cistern is filled to a level up to 1 cm. below the
working water level.
Discharge Capacity
When tested in accordance with IS 7231, cistern of 5 litres and 10 litres capacities, when required
to give a full flush, shall respectively discharge 5 litres and 10 litres with variation of ± 0.5 litres. Dual-
flush cistern of 10 litres capacity shall discharge alternatively a short flush of 5 ± 0.5 litres. Dual flush
cistern of 6/3 litres capacity shall discharge 6 ± 0.5 litres and alternatively a half flush of 3 ± 0.5 litres.
Discharge Rate
When tested in accordance with IS 7231, the discharge rate shall be 10 ± 0.5 litres within 6
seconds and 5 ± 0.5 litres within 3 seconds for cistern of capacities 10 litres and 5 litres and 6 ± 0.5
litres within 6 second and 3 ± 0.5 litres within 3 second for cistern of 6/3 litres capacity respectively.
The cistern shall be so designed that there is no appreciable variation in the force of the flush during
the discharge of the required quantity of water. For coupled cisterns, this test shall not be applicable.
Special Requirements
Distortion Resistance Test

The cisterns, complete with its fittings, shall be installed and filled with water to the marked water
line and observed for any distortion. The cistern shall not budge more than 6 mm and the cover shall
not be dislodged.
Dead Load Test

When the flushing mechanism incorporates chain pull or hand operated lever, the cistern, complete
with its fittings, when installed and filled with water to the marked water line and tested by the application
of a dead load of 230 N applied 6 mm from the end of the operating lever arm for 30 seconds, shall
not distort to such an extent that any part becomes detached. In the case of other operating mechanism,
the dead load applied shall be a mass equivalent to the operating force required to overcome the
normal hydrostatic head; Thirty seconds after the load is removed, the function and appearance of
the cistern shall not be impaired.
Front Thrust Test

The front thrust test shall be applied only to cisterns intended for low level use. The cistern
complete with its fittings, when installed and filled with water to the marked water line and tested by
the method described in IS 7231, shall not distort to such an extent as to be inoperable or unsightly
when the load is removed.
Impact Test
The cistern, complete with its fittings, when installed and filled as described in IS 7231 shall show
no defect after one impact. Repeat the test but with the cistern empty. The cistern shall show no
defect after the further impact.
17.1.2 Draining Board

Draining board made of Glazed fireclay conforming to C.P.W.D. Specifications and as per directions
of Engineer-in-Charge, shall be provided. The size of the board shall be as specified. The entire
surface including bottom of the board shall be finished smooth.

17.1.3 Foot Rests (Fig. 17.4)
Foot rests shall be of Vitreous China conforming to IS 2556 (Part- X). Foot rests which are
rectangular shall meet the minimum requirements and dimensions shown in Fig. 17.4 and may be of
different designs where so specified. Foot rests of different shapes and sizes shall also be allowed
subject to approval of Engineer-in-Charge.
17.1.4 Glass Shelf/PVC Shelf

Glass shelf shall consist of an assembly of glass shelf, with anodised aluminium angle frame to
support the glass shelf. The shelf shall be of glass of best quality with edges rounded off, and shall
be free from flaws specks or bubbles. The size of the shelf shall be 60 x 12 cm unless otherwise
specified and thickness not less than 5.5 mm. The shelf shall have C.P. brass brackets which shall be
fixed with C.P. brass screws to rawl plugs firmly embedded in the walls.
PVC shelf as per manufacturer’s specifications and size as specified shall be provided.
17.1.5 Mirror
The mirror shall be of superior glass with edges rounded off or beveled, as specified. It shall be
free from flaws, specks or bubbles. The size of the mirror shall be 60 x 45 cm unless specified
otherwise and its thickness shall not be less than 5.5 mm. It shall be uniformly silver plated at the
back and shall be free from silvering defects. Silvering shall have a protective uniform covering of
red lead paint. Where beveled edge mirrors of 5.5 mm thickness are not available, fancy looking
mirrors with PVC beading/border or aluminium beading or stainless steel beading/border based on
manufacture’s specifications be provided nothing extra shall be paid on this account. Backing of
mirrors shall be provided with environmentally friendly material other than asbestos cement sheet.
17.1.6 M.S. Stays and Clamps (Fig. 17.5)

The clamps shall be made from 1.5 mm thick M.S. flat of 32 mm width, bent to the required shape
and size to fit tightly on the socket, when tightened with nuts & bolts. It shall be formed of two semicircular
pieces with flanged ends on both sides with holes to fit in the screws, bolts and nuts 40 mm long. The
stay shall be minimum one metre long of 10 mm dia M.S. bar. One end of the stay shall be bent for
embedding in the wall in cement concrete block of size 20 x 10 x 10 cm in 1:2:4 mix (1 cement : 2
coarse sand : 4 graded stone aggregate 20 mm nominal size). The concrete shall be finished to
match with the surrounding surface.
17.1.7 Pillar Taps

Pillar taps shall be chromium plated brass and shall conform to IS 1795. The nominal sizes of the
pillar tap shall be 15 mm or 20 mm as specified. The nominal size shall be designated by the nominal
bore of the pipe outlet to which the tap is to be fitted. Finished weights of 15 mm and 20 mm pillar
taps shall be as prescribed in Table 17.2.
TABLE 17.2
Minimum Finished Weights of Pillar Taps
Particulars Weights in gms
15 mm size 20 mm size
Body 255 505
Washer plate loose valve 15 28
Back nut 40 50
Tap 650 1175

Casting shall be sound and free from laps, blow hole and pitting. External and internal surfaces
shall be clean, smooth and free from sand and be neatly dressed. The body, bonnet and other parts
shall be machined true so that when assembled, the parts shall be axial, parallel and cylindrical with
surfaces smoothly finished.
The area of waterway through the body shall not be less than the area of the circle of diameter
equal to the bore of the seating of the tap. The seating of pillar tap shall be integral with the body and
edges rounded to avoid cutting of washer. Pillar taps shall be nickel chromium plated and thickness
of coating shall not be less than service grade No. 2 of IS 4827 and plating shall be capable of taking
high polish which shall not easily tarnish or scale.
Every pillar tap, complete with its component parts shall withstand an internally applied hydraulic
pressure of 20 Kg/sq. cm maintained for a period of 2 minutes during which period it shall neither
leak nor sweat.
17.1.8 Sand Cast Iron or Centrifugally Cast (Spun) Iron Pipes and Fittings
Sand cast iron spigot and socket soil, waste and ventilating pipes, fittings and accessories shall
conform to IS 1729. Centrifugally cast (Spun) iron spigot and socket soil, waste and ventilating pipes,
fittings and accessories shall conform to IS 3989.
The fittings shall conform to the same I.S. specifications to which the pipe itself conforms in which
they are connected.
The pipes shall have spigot and socket ends, with head on spigot end in case of sand cast iron
pipes and without head on spigot end in case of cast iron (Spun) pipes. The pipes and fittings shall
be true to shape, smooth and cylindrical, their inner and outer surface being as nearly as practicable
concentric. They shall be sound and shall be free from cracks, taps, pinholes and other imperfections
and shall be neatly dressed and carefully fettled. All pipes and fittings shall ring clearly when struck
with a light hand hammer.
The ends of pipes and fittings shall be reasonably square to their axis. The sand cast iron pipes
shall be 1.5/1.8/2.0 metre in length including socket ends, cast iron (Spun) pipes shall be 1.5/1.75/
2.0/2.5/3.0 metre in length excluding socket ends, unless shorter lengths are either specified or
required at junctions etc. The pipe and fittings shall be supplied without ears, unless specified or
directed otherwise.
All pipes and fittings shall be coated internally and externally with the same material at the
factory, the fitting being preheated prior to total immersion in a bath containing a uniformly heated
composition having a tar or other suitable base. The coating material shall have good adherence
and shall not scale off. In all instances where the coating material has tar or similar base it shall be
smooth and tenacious and hard enough not to flow when exposed to a temperature of 77 degree
centigrade but not so brittle at a temperature of 0 degree centigrade as to chip off when scribed
lightly with a pen knife.
The standard weights and thicknesses of pipes and their tolerances shall be as prescribed in
Appendix A.
The thickness of fittings and their socket and spigot dimensions shall conform to the thickness
and dimensions specified for the corresponding sizes of straight pipes. The tolerance in weights &
thicknesses shall be the same as for straight pipes.
The access door fittings shall be designed so as to avoid dead spaces in which filth may
accumulate. Doors shall be provided with 3 mm rubber insertion packing and when closed and
bolted, these shall be water tight.

Sand Cast Iron Floor Trap or Nahani Trap
Sand cast Iron Floor trap or Nahani trap shall be ‘P’ or ‘S’ type with minimum 50 mm seal. However,
if the plumbing is in two pipe system and with a gully trap at the ground level the minimum water seal
shall be 35 mm. The traps shall be of self cleansing design and shall have exit of same size as that
of waste pipe. These shall conform to IS 1729.
17.1.8A HUBLESS CENTRIFUGALLY CAST (SPUN) IRON PIPES AND FITTINGS

Hubless Centrifugally Cast (Spun) Iron Pipes and Fittings soil, waste and ventilating pipes, fittings
and accessories shall conform to IS 15905.
The hubless centrifugally cast (spun) iron pipes shall have plain both ends (spigot type), without
sockets. The pipes and fittings shall be true to shape, smooth and cylindrical, their inner and outer
surface being as nearly as practicable concentric. They shall be sound and shall be free from cracks,
taps, pinholes and other imperfections and shall be neatly dressed and carefully fettled. All pipes
and fittings shall emit a clear ringing sound when struck with a light hand hammer.
The ends of pipes and fittings shall be reasonably square to their axis. The hubless centrifugally
cast iron pipes shall be 3.0 metre or more in length.
All pipes and fittings shall be coated internally and externally with the epoxy coating material at
the factory, the fitting being preheated prior to total immersion in a bath containing a uniformly
heated composition. The coating material shall have good adherence and shall not scale off.
The tolerance in diameter of pipes shall be as prescribed in Table-17.2A below :
Table-17.2A
External Diameters and Tolerances
Tolerance on External diameter

Nominal size External Diameter
Sl. No. DE
DN (in mm) DE (in mm)
(in mm)
(1) (2) (3) (4)
1 50 58 +2
-1
2 75 83 +2
-1
3 100 110 +2
-2
4 150 160 +2
-2
5 200 210 +2.5
-2.5
The thickness of fittings and spigot dimensions shall conform to the thickness and dimensions
specified for the corresponding sizes of straight pipes. The nominal & minimum thicknesses of pipes
& fittings shall be as per Table-2 below:

Table-2
Nominal & Minimum Thickness of Pipes & Fittings
Thickness ‘e’ mm
Nominal size
Sl. No. Pipe Fittings
(DN)
Nominal Minimum Nominal Minimum
(1) (2) (3) (4) (5) (6)
i) 50 3.5 3.0 4.2 3.0
ii) 75 3.5 3.0 4.2 3.0
iii) 100 3.5 3.0 4.2 3.0
iv) 150 4.0 3.5 5.3 3.5
v) 200 5.0 4.0 6.0 4.0
The access door fittings shall have no dead spaces in which filth may accumulate. Doors shall be provided
with 3 mm rubber insertion packing and when closed and bolted, these shall be water tight.
Joints:
The pipes and fittings may assembled using various types of joints, The joints are intrinsic components of
the drainage, whose characteristics and tolerances shall be specified in the manufactures catalogues.
Taking into account the different applications of cast iron pipe work systems, various joint designs are
permitted provided that they satisfy the requirement to this standard. The joints shall incorporate one or more
EPDM rubber gasket(s) to ensure leak tightness and prevent direct contact between the ends of pipes, fittings
and accessories.
Materials for coupling of clamping components shall usually be made from:
(a) Ductile iron of grade 500/7 as per IS 1865,
or
(b) Stainless steels in accordance with IS 1570 (Part 5) in order to ensure resistance to corrosion and
a stabilization against the austenitic stainless steel with at least 17 percent chrome and 9 percent
nickel of equivalent, or from material of comparable resistance.
(c) Ductile iron couplings of clamping components shall be coated internally and externally.
(d) All parts of the joints shall free from defects likely to compromise their suitability for use.
17.1.9 Plastic Seat and Covers for Water Closet (Fig. 17.6)
The seat and cover shall be of thermosetting or thermoplastic conforming to IS 2548 (Part-1) or of
thermoplastic confirming to IS 2548 (Part-2) as specified. Unless otherwise specified these shall be of closed
pattern.
17.1.9.1 Thermosetting plastic used shall conform to grade 2 or 3 of IS 1300 when it is phenolic plastic or IS
3389 when of urea formaldehyde.
Thermo plastic materials used may be of Polystyrene conforming to type 2 or 3 of IS 2267 or of polypropylene,
Appendix A of IS 2548. In public buildings where rough and heavy use of seats and covers are common,
plastic seats shall be moulded out of thermosetting materials, phenolic or urea formaldehyde only and the
underside of the seat shall be flat with solid moulding.
17.1.9.2 The hinging device shall be bronze or brass with nickel chromium plating confirming to IS 1068 and
the seat shall have not less than three rubber or plastic buffers of size 25 mm x 40 mm x 10 mm for closed
front seats and not less than four for open front seats, which shall be securely fixed to the underside of the
seat unless otherwise specified. The cover shall be fitted with the same number of buffers as provided for
the seat.

17.1.9.3 Seats shall have a smooth finish and shall be non absorptive and free from cracks and
crevices. They shall be capable of being easily cleaned and shall not be adversely affected by
common solvents or household cleanser.
17.1.9.4 Strength: The seats shall withstand without permanent distortion of the seat or hinge
fittings or damage to any finish, a load of 1150 N for 30 minutes applied in the manner prescribed in
IS 2548.
17.1.10 Sinks (Fig. 17.7)

Laboratory sinks and Kitchen sinks shall be of white glazed fire clay confirming to IS 771 (Part-2)
with up to date amendments. The kitchen sink shall be of one piece construction with or without rim
but without overflow.
17.1.10.1 Stainless steel kitchen sink shall be of sizes as specified and shall be conforming to IS
13983 (Fig. 17.7).
17.1.11 Towel Rail

The towel rail shall be of PTMT as specified and as per direction of Engineer-in-charge.
17.1.12 Toilet Paper Holder

The toilet paper holder shall be of CP brass or vitreous china as specified and of size and design
as approved by the Engineer-in-Charge. It shall be fixed in position by means of C.P. brass screws
and rawl plugs embedded in the wall.
17.1.13 Urinals
17.1.13.1 Bowl Type Urinals (Fig. 17.9 & 17.10) : Urinal basins shall be of flat back or corner wall
type lipped in front. These shall be of white vitreous china conforming to IS 2556-(Part 6). The
urinals shall of one piece construction. Each urinal shall be provided with not less than two fixing
holes of minimum dia 6.5 mm on each side. Each urinal shall have an integral flushing rim of suitable
type and inlet or supply horn for connecting the flush pipe. The flushing rim and inlet shall be of the
self draining type. It shall have a weep hole at the flushing inlet of the urinals.
At the bottom of the urinal an outlet horn for connecting to an outlet pipe shall be provided. The
exterior of the outlet horn shall not be glazed and the surface shall be provided with grooves at right
angles to the axis of the outlet to facilitate fixing to the outlet pipe. The inside surface of the urinal
shall be uniform and smooth throughout to ensure efficient flushing. The bottom of pan shall have
sufficient slope from the front towards the outlet such that there is efficient draining.
17.1.13.2 Half Stall Urinals (Fig. 17.11) : They shall be of white vitreous China conforming to IS
2556 (Part 6). They shall be of one piece construction with or without an integral flushing box rim
and provided with slots or alternative fixing arrangement at the flat back end. They shall be provided
with ridges where integral flushing rim is not provided in the sides of the interior of the bowl, to
divert the water towards the front line of the urinal where integral flushing box rim is specified,
water spreaders provided shall conform to IS 2556 Part-6 (Fig. 17.13) . These shall be vitreous
China of one piece construction with integral flush inlet. The tolerance of ± 4 per cent may be
allowed on the dimensions specified.
17.1.13.3 Urinal Partition Slabs : Urinal Partition slabs shall be provided, as specified in the item
of work.

17.1.13.4 Squatting Plate Urinal (Fig. 17.12) : The plates shall be of white vitreous china conforming
to IS 2556 (Part-1) and IS 2556 (Part-6) with internal flushing rim with front or side inlet. Squatting
Plate shall be of one piece construction. Each urinal shall have integral longitudinal flushing pipe of
suitable type which may be connected to flush pipe. These shall be 100 mm dia white glazed vitreous
china channel with stop and outlet piece in front.
17.1.14 Wash Basins (Fig. 17.14, 17.15, 17.16, 17.17 & 17.18)
Wash basins shall be of white vitreous china conforming to IS 2556 (Part -I) and IS 2556 (Part-4).
Wash basins either of flat back or angle back as specified shall be of one piece construction, including
a combined overflow. All internal angles shall be designed so as to facilitate cleaning. Each basin
shall have a rim on all sides, except sides in contact with the walls and shall have a skirting at the
back. Basins shall be provided with single or double tap holes as specified. The tap holes shall be 28
mm square or 30 mm round or 25 mm round for pop up hole. A suitable tap hole button shall be
supplied if one tap hole is not required in installation. Each basin shall have circular waste hole to
which the interior of basin shall drain. The waste hole shall be either rebated or beveled internally
with dia meter of 65 mm at top. Each basin shall be provided with a non-ferrous 32 mm waste fitting.
Stud slots to receive the brackets on the underside of the wash basin shall be suitable for a bracket
with stud not exceeding 13 mm diameter, 5 mm high and 305 mm from the back of basin to the centre
of the stud. The stud slots shall be of depth sufficient to take 5 mm stud. Every basin shall have an
integral soap holder recess or recesses, which shall fully drain into the bowl. A slot type of overflow
having an area of not less than 5 sq. cm, shall be provided and shall be so designed as to facilitate
cleaning of the overflow.
Where oval shape or round shape wash basins are required to be fixed these shall be fixed
preferably in RCC platform with local available stone topping either fully sunk in stone top or top flush
with the stone topping as directed by Engineer-in-Charge.
The wash basins shall be one of the following patterns and sizes as specified (Fig. 17.14).
(a) Flat back: 660 x 460 mm (Surgeon’s Basin)

630 × 450 mm
550 × 400 mm
450 × 300 mm
(b) Angle back: 600 × 480 mm 400 × 400 mm
White glazed pedestals for wash basins, where specified shall be provided. The quality of the
glazing of the pedestal shall be exactly the same as that of the basin along with which it is to be
installed. It shall be completely recessed at the back to accommodate supply and waste pipes and
fittings. It shall be capable of supporting the basin rigidly and adequately and shall be so designed
as to make the height from the floor to top of the rim of basin 75 to 80 cm as shown in Fig. 17.14,
17.15, 17.16, 17.17 & 17.18. All the waste fittings shall be brass chromium plated, or as specified.
17.1.15 Waste Fittings for Wash Basins and Sinks (Fig. 17.8)
The waste fittings shall be of nickel chromium plated brass, with thickness of plating not less than
service grade 2 of IS 4827 which is capable of receiving polish and will not easily scale off. The fitting
shall conform in all respect to IS 2963 and shall be sound, free from laps, blow holes and fittings and
other manufacturing defects. External and internal surfaces shall be clean and smooth. They shall
be neatly dressed and be truly machined so that the nut smoothly moves on the body.
Waste fitting for wash basins shall be of nominal size of 32 mm. Waste fittings for sinks shall be of
nominal size 50 mm.

17.1.16 Water Closet (Fig. 17.19, 17.20, 17.21, 17.22 & 17.23)
17.1.16.1 Squatting Pans (Indian Type W.C.) (Fig. 17.19, 17.20 & 17.21) : Squatting pans shall be
of white vitreous china conforming to IS 2556 Part-I for General Requirements and relevant IS codes
for each pattern as described below:
(i) Long pattern-conforming to IS 2556 (Part-3).
(ii) Orissa pattern-conforming to IS 2556 (Part-3).
(iii) Integrated type conforming to IS 2556 (Part-14).
Preferably Orissa type pan should be used.

Each pan shall have an integral flushing rim of suitable type. It shall also have an inlet or supply
horn for connecting the flush pipes, as shown in Fig. 17.19, 17.20 & 17.21. The flushing rim and inlet
shall be of the self draining type. It shall have weep hole at the flushing inlet to the pan. The flushing
inlet shall be in the front, unless otherwise specified or ordered by the Engineer-in- Charge. The
inside of the bottom of the pan shall have sufficient slope from the front towards the outlet and the
surface shall be uniform and smooth to enable easy and quick disposal while flushing. The exterior
surface of the outlet below the flange shall be an unglazed surface which shall have grooves at right
angles to the axis of the outlet. In all cases a pan shall be provided with a (100 mm) S.C.I. trap ‘P’ or
‘S’ type with approximately 50 mm water seal and 50 mm dia vent horn, where required by the
Engineer-in-Charge.
17.1.16.2 Wash Down Type (European Type W.C.) (Fig. 17.22 & 17.23) : Water closets shall
be of white vitreous china conforming to IS 2556 (Part-1) and 2556 (Part-2), as specified and
shall be of “Wash down type”. The closets shall be either of the two patterns (Pattern I & Pattern
II) and sizes as shown in Fig. 17.22 & 17.23 as specified. The closets shall be of one piece
construction. Each water closet shall have not less than two holes having a minimum diameter of
6.5 mm for fixing to floor and shall have an integral flushing rim of suitable type. It shall also have
an inlet or supply horn for connecting the flushing pipe of dimensions as shown in table in Fig.
17.20 & 17.21 the flushing rim may be boxed or open type. In the case of box rims adequate
number of holes, on each side together with a slot opposite the inlet shall be provided. The
flushing rim and inlet shall be of the self draining type. The water closet shall have a weep hole
at the flushing inlet. Each water closet shall have an integral trap with either ‘S’ or ‘P’ outlet with
at least 50 mm water seal. For P trap, the slope of the outlet shall be 14 deg. below the horizontal.
Where required the water closet shall have an antisiphonage 50 mm dia vent horn on the outlet
side of the trap with dimension conforming to those given in Fig. 17.22 and on either right or left
hand or centre as specified set at an angle of 45 deg. and invert of vent hole not below the
central line of the outlet. The inside surface of water closets and traps shall be uniform and
smooth in order to enable an efficient flush. The serrated part of the outlet shall not be glazed
externally. The water closet, when sealed at the bottom of the trap in line with the back plate,
shall be capable of holding not less than 15 litres of water between the normal water level and
the highest possible water level of the water closet as installed.
17.2 GENERAL REQUIREMENTS FOR INSTALLATION OF W.C. PAN

17.2.1 The work shall be carried cut, complying in all respects with the requirements of relevant bye-
laws of the local body in whose jurisdiction the work is situated.
17.2.2 Any damage caused to the building, or to electric, sanitary, water supply or other, installations
etc. therein, either due to negligence on the part of the contractor, or due to actual requirements
of the work, shall be made good and the building or the installation shall be restored to its original
condition by the contractor. Nothing extra shall be paid for such restoration works except where
otherwise specified.

17.2.3 For making good the damage to the under mentioned items of work, the specifications as
given in the following paras shall apply, unless directed otherwise.
(a) Masonry Work: The masonry work shall be made good by using the same class of bricks,
tiles or stones as was damaged during the execution of the work. The mortar used shall be
cement mortar 1:5 (1 cement: 5 fine sand) or as directed by the Engineer-in-Charge.
(b) Plain Concrete Work : Concrete work for sub-grade of the flooring, foundations and other
plain concrete works shall be cement concrete 1:5:10 (1 cement : 5 coarse sand : 10 graded
stone aggregate 40 mm nominal size). A coat of neat cement slurry shall be applied at the
junction with old work, before laying fresh concrete.
(c) Cement Concrete Flooring and R.C.C. Work : Cement concrete 1:2:4 (1 Cement : 2
Coarse sand : 4 graded stone aggregate 20 mm nominal size) shall be used after applying
a coat of neat cement slurry at the junction with old work, and the surface finished to match
with the surrounding surface.
(d) Plastering: Cement plaster 1:4 (1 cement: 4 sand) shall be used. The sand shall be fine or
coarse, as used in the original work. The surface shall be finished with two or more coats of
white wash, colour wash, distemper or painting as required, but where the surface is not to
be white washed, colour washed, distempered or painted, it shall be finished as required to
match with the surrounding surface.
(e) Other Items: Damage to any other item shall be made good as directed by the Engineer-in-
Charge.
Note: In all the above operations the damaged portion shall be cut in regular geometric
shape and cleaned before making good the same.
17.2.4 All exposed G.I., C.I. or lead pipes and fittings shall be painted with approved quality of paint
and shade as specified. The painting work shall conform to specification described under SH: Painting.
17.2.5 All sanitary and plumbing work shall be carried out through licensed plumbers.
17. 2.6 On completion of the work the site shall be cleaned and all rubbish disposed off as directed
17.2.7 Various sanitary fittings described under 17.1 including fixing shall be enumerated individually
or in combination under relevant items of works as described below. When used in combination,
specifications as described under relevant paras shall apply but nothing extra shall be paid for
making connections required for successful functioning of the combination.
17.3 INSTALLATION OF DRAINING BOARD

17.3.1 Fixing
One end of the board shall rest on sink and the other end shall be supported on C.I. bracket
embedded in cement concrete (1:2:4) block 100 × 75 × 150 mm. The brackets used shall be of
cantilever type or wall fixed type as for the sink.
17.3.2 Painting
The brackets shall be painted with two or more coats of approved paint.
17.3.3 Measurements
Draining board shall be measured in numbers.
17.3.4 Rate
The rate shall include the cost of all materials and labour involved in all operations.

17.4 INSTALLATIONS OF FLUSHING CISTERN
17.4.1 Fixing
17.4.1.1 Low Level Cistern: The cistern shall be fixed on C.I. cantilever brackets which shall be
firmly embedded in the wall in cement concrete (1:2:4) block 100 x 75 x 150 mm. Connection between
cistern and closet shall be made by means of 40 mm dia flush bend with rubber or G.I. inlet connection
as specified.
17.4.1.2 Automatic Cistern: Clause 17.4.1.1 shall apply except that CP Brass stop cock shall be
provided for cistern having a capacity of more than 5 liter. The main & distribution flush pipe shall be
fixed to the wall by means of standard pattern holder bat clamp shown in Fig. 17.5.
17.4.2 Painting
The brackets shall be painted, if specified, with two or more coats of paint of approved shade and
quality.
17.4.3 Measurements
Cistern, including all fittings, shall be measured in numbers.
17.4.4 Rate
above.
17.5 INSTALLATION OF MIRROR

17.5.1 Fixing
The mirror shall be mounted on backing with environmentally friendly material other than asbestos
cement sheet shall be fixed in position by means of 4 C.P. brass screws and C.P. brass washers,
over rubber washers and wooden plugs firmly embedded in walls. C.P. brass clamps with C.P. brass
screws may be an alternative method of fixing, where so directed. Unless specified otherwise the
longer side shall be fixed horizontally.
17.5.2 Measurements
Mirror shall be measured in numbers.
17.5.3 Rate
Rate shall include the cost of all the materials and labour involved in all the operations
described above.
17.6 FIXING AND JOINTING OF PIPES AND FITTINGS

17.6.0 The specifications described in sub-head 12.0 shall apply, as far as applicable, except that
the joint shall be lead caulked. All soil pipes shall be carried up above the roof and shall have sand
cast iron terminal guard.
17.6.1 Height of Ventilating Pipes

The ventilating pipe or shaft shall be carried to a height of at least 60 cms above the outer
covering of the roof of the building or in the case of a window in a gable wall or a dormer window it
shall be carried up to the ridge of the roof or at least 2 metres above the top of the window. In the
case of a flat roof to which access for use is provided it shall be carried up to a height of 2 metres
above the roof and shall not terminate within 2 metres, measured vertically from the top of any
window opening which may exist up to a horizontal distance of 3 meters from the vent pipe into such
building and in no case shall be carried to a height less than 3 metres above plinth level. In case the
adjoining building is taller, the ventilating pipe shall be carried higher than the roof of the adjoining
building, wherever it is possible.

The pipes above the parapet shall be secured to the wall by means of M.S. stay and clamps as
specified in 17.1.6.
The connections between the main pipe and branch pipes shall be made by using branches and
bends with access doors for cleaning. The waste from lavatories, kitchen, basins, sinks, baths and
other floor traps shall be separately connected to respective waste stack of upper floors. The waste
stack of lavatories shall be connected directly to manhole while the waste stack of others shall
separately discharge over gully trap. Where single stack system is provided, the connection shall be
made direct to the manhole.
17.6.2 Jointing
The interior of the socket and exterior of the spigots shall be thoroughly cleaned and dried. The
spigot end shall be inserted into the socket right up to the back of the socket and carefully centered
by two or three laps of treated spun yarn, twisted into ropes of uniform thickness, well caulked into
the back of the socket. No piece of yarn shall be shorter than the circumference of the pipe. The
jointed pipe line shall be at required levels and alignment.
The leading of pipes shall be made by means of ropes covered with clay or by using special
leading rings. The lead shall be melted so as to be thoroughly fluid and each joint shall be filled in
one pouring.
The following precautions shall be taken for melting lead:

(a) The pot and the ladle in which lead shall be put shall be clean and dry.
(b) Sufficient quantity of lead shall be melted.
(c) Any scum or dross which may appear on the surface of the lead during melting shall be
skimmed off.
(d) Lead shall not be overheated.
After the lead has been run into the joint the lead shall be thoroughly caulked. Caulking of joints
shall be done after a convenient length of the pipes has been laid and leaded.
The leading ring shall first be removed and any lead outside the socket shall be removed with a
flat chisel and then the joint caulked round three times with caulking tools of increasing thickness
and hammer 2 to 3 kg. weight. The joints shall not be covered till the pipe line has been tested under
pressure.
Use of collars for jointing is not permitted in any concealed or embedded location. However, in
exposed locations where full length pipes cannot be fixed due to site constraints, collars (and not
loose sockets) may be used subject to the following:
(a) No two consecutive joint shall be with the use of collars.
(b) The joint of collar with the cut/spigot end of the pipe shall be made on the ground in advance
and tested against leakage before fixing.
(c) Cut/spigot end of the pipes shall be inserted in the collars up to the projection inside the
collar and jointing shall be done as in the case of socket and spigot joint. The jointed pipe
line shall be at required level/slope and alignment.

As marked in fig Pipe dia (size in mm)
50 75 100 150
a 76 101 129 181
b 50 75 100 150
c 10 10 10 10
d 79 89 95 108
e 89 101 114 140
Note: The dimensions of loose sockets shall correspond to those of appropriate nominal size of pipe.
17.6.3 Testing
In order to ensure that adequate lead is poured properly into the joints and to control waste in
use of lead, at the beginning of work three or four sample joints shall be made and the quantum of
lead per joint approved by the Engineer-in-Charge. All sand cast iron/cast iron (Spun) pipes and
fittings including joint shall be tested by smoke test to the satisfaction of the Engineer-in-Charge and
left in working order after completion. The smoke test shall be carried out as under:
Smoke shall be pumped into the pipes at the lowest end from a smoke machine which consists of
a bellow and burner. The material usually burnt is greasy cotton waste which gives out a clear
pungent smoke which is easily detectable by sight as well as by smell, if there is leak at any point of
the drain.
17.6.4 Painting
All sand cast iron/cast iron (Spun) pipes and fittings shall be painted with shade to match the
colour of the background as directed by the Engineer-in-Charge.
17.6.5 Measurements
17.6.5.1 The pipes shall be measured net when fixed in position excluding all fittings along its length,
correct to a cm.
17.6.5.2 When collars are used for jointing SCI pipes these shall be measured as fittings and shall
be paid for separately.
17.6.5.3 No allowance shall be made for the portions of the pipe lengths entering the sockets of the
adjacent pipes or fittings. The above shall apply to both cases i.e. whether the pipes are fixed on wall
face or embedded in masonry.
17.6.5.4 No deduction shall be made in the former case from the masonry measurement for the
volume of concrete blocks embedded therein. Similarly no deduction shall be made for the volume
occupied by the pipes from the masonry when the former are embedded in the later.

17.6.6 Rates
above, excluding fittings, lead caulk jointing, the supply and fixing M.S. holder bat clamps and M.S.
stays and clamps, floor trap and painting, which shall be paid for separately.
17.7 INSTALLATION OF SEAT AND COVER TO WATER CLOSET

17.7.1 Fixing
The seat shall be fixed to the pan by means of two corrosion resistant hinge bolts with a minimum
length of shank of 65 mm and threaded to within 25 mm of the flange supplied by the manufacturer
along with the seat. Each bolt shall be provided with two suitably shaped washers of rubber or other
similar materials for adjusting the level of the seat while fixing it to the pans. In addition, one non-
ferrous or stainless steel washer shall be provided with each bolt. The maximum external diameter of
the washer fixed on the underside of the pan shall not be greater than 25 mm. Alternative hinging
devices as supplied by the manufacturer of the seat can also be used for fixing with the approval of
Engineer-in-Charge.
17.7.2 Measurements
Seat with cover shall be measured in numbers.
17.7.3 Rate
Rate shall include the cost of all the materials and labour involved in all the operations described
above.
17.8 INSTALLATION OF SINK

17.8.0 The installation shall consist of assembly of sink C.I. brackets, union and G.I. or P.V.C. waste pipe.
17.8.1 Fixing
The sink shall be supported on C.I. cantilever brackets, embedded in cement concrete (1:2:4)
block of size 100 x 75 x 150 mm. Brackets shall be fixed in position before the dado work is done.
The C.P. brass or P.V.C. union shall be connected to 40 mm nominal bore G.I. or PVC waste pipe
which shall be suitably bent towards the wall and shall discharge into a floor trap. C.P. brass trap
and union and waste shall be paid separately. The height of front edge of sink from the floor level
shall be 80 cm.
17.8.2 Measurements
The sinks shall be measured in numbers.
17.8.3 Rate
Rate shall include the cost of all materials and labour involved in all the operations described
above but shall not included the cost of waste fitting and brackets which shall be paid for separately.
17.9 INSTALLATION OF URINAL LIPPED, HALF STALL (SINGLE OR RANGE) (FIG. 17.9 & 17.11)
17.9.0 Urinal installation shall consist of a lipped urinal (Single or range), an automatic flushing
cistern, G.I. flush and waste pipe. The capacity of flushing cistern and relevant size of flush pipe for
urinals in a range shall be as prescribed in Table 17.3.
Waste pipe shall be of 32 mm nominal bore G.I. pipe and shall be paid separately.
17.9.1 Fixing
Urinals shall be fixed in position by using wooden plugs and screws. It shall be at a height of 65
cm from the standing level to the top of the lip of the urinal, unless otherwise directed by the Engineer
-in-Charge. The size of wooden plugs shall be 50 mm × 50 mm at base tapering to 38 mm × 38 mm
at top and of length 5.0 cms. These shall be fixed in the wall in cement mortar 1:3 (1 cement: 3 fine
sand). After the plug fixed in the wall, the mortar shall be cured till it is set.

TABLE 17.3
No. of Urinals Capacity of Flushing Size of Flush Pipe (Galvanised Iron)
Cistern Main Distribution
One 5 Litres 15 mm 15 mm
Two 10 Litres 20 mm 15 mm
Three 10 Litres 25 mm 15 mm
Four 15 Litres 25 mm 15 mm
Each urinal shall be connected to 32 mm dia waste pipe which shall discharge into the channel or
a floor trap. The connection between the urinal and flush or waste pipe shall be made by means of
putty or white lead mixed with chopped hemp.
17.9.2 Measurements
Urinals shall be measured in numbers.
17.9.3 Rate
above.
17.10 INSTALLATION OF STALL URINAL (SINGLE OR RANGE)

17.10.0 The installation shall consist of stall urinal (single or range), automatic flushing cistern,
C.P. brass standard flush pipes, C.P. brass spreader and C.I. trap with tail piece and outlet grating of
C.P. brass. Capacity of flushing cistern and relevant size of flush pipe, C.I. trap shall be as prescribed
in Table 17.4.
TABLE 17.4
No. of Urinals in Capacity of Size of Flush Pipe (Chromium Plated) Diameter of C.I.
range Flushing cistern Main Distribution Traps
One 05 Litres 15 mm 15 mm 50 mm
Two 10 Liters 20 mm 15 mm 50 mm
Three 15 Litres 25 mm 15 mm 80 mm
Four 15 Litres 25 mm 15 mm 80 mm
17.10.1 Fixing
The floor slab shall be suitably sunk to receive the stall urinal. Where the floor slab is not sunk,
the stall urinal shall be provided over a platform. The lip of the stall urinal shall be flush with the
finished floor level adjacent to it. The stall urinal shall be laid over a fine sand cushion of average 25
mm thickness. A space of not less than 3 mm shall be provided all -round, in front, sides and filled
with water proofing plastic compound. Care shall be taken that after the sub-grade for the floor is
cast, one week should lapse before urinals are installed. The trap and fittings shall be fixed as
directed by the Engineer-in-Charge. Payment for the floor and its sub-grade shall be made separately.
Stall urinals shall be measured in numbers.
17.10.3 Rate
described above.

17.11 INSTALLATION OF WASH BASIN (FIG. 17.14, 17.15, 17.16, 17.17 & 17.18)
17.11.0 The installation shall consist of an assembly of wash basin, pillar taps, C.I. brackets, C.P.
brass or P.V.C. union, as specified. The wash basin shall be provided with one or two 15 mm C.P.
brass pillar taps, as specified. The height of top of the rim of wash basin from the floor level shall be
within 750 mm to 800 mm.
17.11.1 Fixing
The basin shall be supported on a pair of C.I. cantilever brackets conforming to IS 775 and be
embedded in cement concrete (1:2:4) block 100 x 75 x 150 mm. Use of M.S. angle or Tee section as
bracket is not permitted. Brackets shall be fixed in position before dado work is done. The brackets
have been shown in Fig. 17.15. The wall plaster on the rear shall be cut to rest over the top edge of
the basin so as not to leave any gap for water to seep through between wall plaster & skirting of
basin. After fixing the basin, plaster shall be made good and surface finished matching with the
existing one. S.C.I. floor traps conforming to IS 1729 having 50 mm water seal (minimum 35 mm in
two pipe systems with gully trap) should be used. Waste pipes laid horizontally should have gradient
not flatter than 1 in 50 and not steeper than 1 in 10.
The waste water from wash basin shall be discharged directly to vitreous semi-circular open
drain, discharging to a floor trap and finally to the vertical stack (Fig.17.15) on upper floors and in
case of ground floor, the waste water shall be discharged either directly to the gully trap or through
the floor trap (Fig. 17.16). C.P. brass trap and union are not to be used in such situations.
If waste pipe is concealed or crosses the wall, waste water shall be discharged through non
ferrous trap like PVC Engineering plastic or C.P. brass and union (Fig. 17.17) to vertical stack. The
C.P. brass trap and union shall be paid for separately.
Where so specified a 20 mm G.I. puff pipe terminating with a perforated brass cap screwed on it
on the outside of the wall or connected to the antisyphon stack shall be provided.
Wash basins shall be measured in numbers.
17.11.3 Rate
described above.
17.12 INSTALLATION OF SQUATTING PAN

17.12.0 The installation shall consist of squatting pan, flushing cistern, flush pipe and a pair of foot
rests.
17.12.1 Fixing
The pan shall be sunk into the floor and embedded in a cushion of average 15 cm thick cement
concrete 1:5:10 (1 Cement : 5 fine sand : 10 graded brick ballast 40 mm nominal size). The concrete
shall be left 115 mm below the top level of the pan so as to allow flooring and its bed concrete. The
pan shall be provided with a 100 mm S.C.I., P or S type trap with an approximately 50 mm seal and 50
mm dia vent horn, where required by the Engineer-in-Charge. The joint between the pan and the
trap shall be made leak proof with cement mortar 1:1 (1 cement : 1 fine sand).
The squatting pans shall be measured in numbers.

17.12.3 Rate
above. Cost of concrete shall be paid separately.
17.13 INSTALLATION OF WATER CLOSET

17.13.0 Installation shall consist of water closet with seat and cover, flushing cistern and flush bend.
17.13.1 Fixing
The closet shall be fixed to the floor by means of 75 mm long 6.5 mm diameter counter-sunk bolts
and nuts embedded in floor concrete.
Water closets shall be measured in numbers.
17.13.3 Rate
above.
17.14 INSTALLATION OF FOOT RESTS

17.14.1 After laying the floor around squatting pan as specified a pair of foot rests shall be fixed in
cement mortar 1 : 3 (1 cement : 3 coarse sand). The position of foot rests with respect to pan shall be
as per Fig. 17.4.
Pair of foot rests shall be measured in numbers.
17.14.3 Rate
above.
17.15 INSTALLATION OF SQUATTING PLATE (SINGLE OR RANGE) (FIG. 17.12)
17.15.0 The installation shall consist of an assembly of squatting plates (single or range), vitreous
China channel, automatic flushing cistern, flush pipe with fittings spreader and C.I. trap. The capacity
of flushing cistern and relevant size of flush pipes shall be as specified in Table 17.5.
TABLE 17.5
No. of Squatting Capacity of Flushing Size of Flush Pipe (Galvanised Iron)
Plates in range Cistern Main Distribution
One 5 liters — 20 mm
Two 10 liters 25 mm 20 mm
Three 15 liters 32 mm 20 mm
Four 15 liters 32 mm 20 mm
17.15.1 Fixing
The floor slab shall be suitably sunk to receive the squatting plate. Where the floor slab is not
sunk, the plates shall be provided over a platform. The top edge of the squatting plate shall be flush
with the finished floor level adjacent to it. It shall be embedded on a layer of 25 mm thick cement
mortar 1:8 (1 cement: 8 fine sand) laid over a bed of cement concrete 1:5:10 (1 cement: 5 fine sand:
10 graded brick aggregate 20 mm nominal size).

There shall be 100 mm dia, white glazed vitreous China channels with stop and outlet pieces
suitably fixed in the floor in cement mortar 1:3 (1 cement :3 coarse sand) and joint finished with white
cement. The squatting plate shall have 1200 high and half brick thick wall in front and on either side
of the squatting plate. The brick work for the walls shall be paid separately. The exposed surface of
walls shall be lined with white glazed tiles with proper corners and angles set in neat cement mortar,
the face of the joints shall be gone over with whiting so as to match with the colour of the tiles. The
tiles shall be 15 mm square. Space if any, left between the side walls and squatting plate shall be
finished white to match the colour of the squatting plate. The trap and fittings shall be fixed as
directed by the Engineer-in-Charge. The vitreous China channel shall discharge into 65 mm diameter
standard urinals, C.I. trap with vent arm having 65 mm C.P. brass outlet grating.
Squatting plates shall be measured in numbers.
17.15.3 Rate
described above.
17.16 INSTALLATION OF TOWEL RAIL

It shall be fixed in position by means of C.P. brass screws on wall surface by PVC dash fasteners,
firmly embedded in wall.
Tower rails shall be measured in numbers.
17.16.2 Rate
Rate shall include the cost of all the materials and labour involved in all the operations
described above.
17.17 INSTALLATION OF STAINLESS STEEL SINK:- Stainless steel A ISI 304 (18/8) kitchen sink.
The installation shall consist of assembly of sink C.I. brackets, union and G.I. or P.V.C. waste pipe.
17.17.1 Fixing
The stainless steel sink shall be fixing as per IS:13983 and shall be supported on C.I. cantilever
brackets, embedded in cement concrete (1:2:4) block of size 100 x 75 x 150 mm. Brackets shall be
fixed in position before the dado work is done. The C.P. brass or P.V.C. union shall be connected to
40 mm nominal bore G.I. or PVC waste pipe which shall be suitably bent towards the wall and shall
discharge into a floor trap. C.P. brass trap and union and waste shall be paid separately. The height
of front edge of sink from the floor level shall be 80 cm.
17.17.2 DIMENSIONS AND TOLERANCES

17.17.2.1 Thickness of Sheet/Strip
17.17.2.2 Nominal thickness of stainless steel sheet/ strip used in the construction of sink shall be
not less than 1.00 mm before forming.
17.17.2.3 Thickness at any point of sink, after forming, shall not be less than 0.75 mm.
17.17.3 Depth of Bowls

The depth of the sink bowl shall be 150 mm minimum, when measured from the top edge of the
bowl to the base of the sink.
NOTE - Depth of smaller bowl shown in Fig. 1 for Type E2 and E3 may be reduced up to 100 mm.

17.17.4 Internal Dimensions of Bowls
The minimum internal dimensions, when measured on the bowl centre lines across the top of the bowl.
shall be 380 mm x 340 mm for rectangular bowls and 360 mm for round bowls.
NOTES I. There is no restriction on bowl shape provided the minimum dimensions given in this clause are
complied with.
1. Internal width of smaller bowl shown in FIg. 1 for Type E2 and E3 may be reduced as per the
manufacturers design.
17.17.5 Bowl Locating Limits

17.17.5.1 The distance between the edge of the sink bowl and the end of the sink shall be 15 mm minimum
for sit-on type sinks and 30 mm minimum for inset type sinks. Depth of the collar provided for inset sinks shall
be 10 ± 2 mm,
17.17.5.2 For sinks designed for use with a 600 mm wide work top, the distance between the edge of the sink
bowl and the front of the sink shall be 50 mm minimum and in the case of sinks designed for use with 500 mm
wide worktop, the distance shall be 45 mm minimum.
17.17.5.3 Both single and double bowl sink shall be set a minimum of 10 mm from gridline.
The sinks shall be measured in numbers.
17.17.7 Rate
Rate shall include the cost of all materials and labour involved in all the operations described above but
shall not included the cost of waste fitting and brackets which shall be paid for separately.
17.18 CUTTING CHASE IN MASONRY WALL
17.18.1 Cutting chasing in brick masonry wall shall be has specified in item no. 18.22.
17.18.2 Filling chases

After sand cast iron/ centrifugally cast/spun iron pipe etc. are fixed in chases, the chases shall be filled
with cement concrete 1:3:6 (1 cement: 3 coarse sand: 6 graded stone aggregate 12.50 mm nominal size) or
cement mortar 1:4 (1 cement: 4 coarse sand) as may be specified or otherwise directed by the Engineer-in-
Charge and made flush with the masonry surface. The concrete surface shall be roughened with wire brushes
to provide a key for plastering.
Chases shall be measured in running meter correct to a cm.
17.18.4 Rates
The rate shall include the cost of labour the materials involved in all the operations described above
excluding the cost of providing pipes etc. which shall be paid separately.
17.19 PAINTING SYNTHETIC ENAMEL PAINT ON SCI/CENTRIFUGALLY CAST (SPUN) IRON SOIL,
WASTE AND VENT PIPES.
17.19.1 The primer and paint of approved brand and manufacturer shall be used as specified. Paint shall be
synthetic enamel paint of any color such as chocolate, grey or buff etc.
17.19.2 Painting new surface

17.19.2.1 Preparation of surface:- The surface of pipe and fittings shall be thoroughly cleaned. All unevenness
shall be rubbed down and made them smooth with sand paper and dust shall be removed properly. After
obtaining approval of Engineer-in-Charge, for SCI/CI pipe, the priming coat shall be applied before the pipe is
fixed in position.

17.19.2.2 Application:- The primer shall be applied with brushes properly on the pipe surface and spread
even and smooth. The application of synthetic enamel paint over priming coat shall be carried out after drying
of primer surfaces. Additional finishing coat shall be applied if found necessary, to ensure proper uniform
surface. The two coats of synthetic enamel paint shall be applied . The second coat shall be applied when the
previous coat has dried up.
17.19.3 Measurement:- Measurement shall be taken over the finished line of pipe including specials and
fittings such as socket, tee, bend, cowl, holder bat clamp etc. in running meter correct to a centimeter. Pipe
of different diameter shall be measured and paid for separately.
17.19.4 Rate:- The rate shall be inclusive of cost of all materials and labours involved in all the operations
described above including painting all specials and fittings etc.
17.20 REPAINTING SCI / CENTRIFUGALLY CAST (SPUN) IRON SOIL, WASTE AND VENT PIPE
17.20.1 The synthetic enamel paint of approved brand and manufacturer shall be used as specified .
17.20.2 Painting old surface.

17.20.2.1 Preparation of surface:- The old surface shall be cleaned off by removing grease, smoke etc. The
surface of pipe shall then be thoroughly cleaned, rubbed down with sand paper and dusted. Rusted patches
shall be cleared up and touched with synthetic enamel paint. If the old paint is blistered and flaked, it shall
be completely removed as described in 13.41. Such removal shall be paid for separately and painting shall be
treated as on new work.
17.20.2.2 Application:- The paint shall be applied with brushes properly on the pipe surface and spread even
and smooth. The one coat of paint to be applied . Additional finishing coat shall be applied if found necessary
to ensure proper uniform surface.
17.20.3 Measurement:- Same as described in the 17.19.3.
17.20.4 Rate:- The rate shall be inclusive of cost of all materials and labours involved in all the operations
described above, including painting all specials and fittings etc.
17.21 INSTALLATION OF WALL MOUNTING WATER CLOSET (WC)

It shall consist of white vitreous china extended wall mounting WC of size 780x370x690 mm of approved
shape, brand and manufacture with duel flush fitting of flushing capacity 3 Ltr / 6 Ltr (adjustable to 4 Ltr/8 Ltr)
including seat cover and cistern fittings, nuts, bolts and gasket etc. complete in all respect as per direction of
Engineer-in-Charge. Wall mounting water closet shall be of white vitreous China confirming to IS 2556 (Part
16) : 2002. For general requirement relating to terminology, materials, manufacture, glazing, defects, minimum
thickness, tolerances, performance and methods of tests shall confirm to IS 2556 (Part 1). Wall mounted
water closet shall be of one piece construction. Each wall mounted water closet shall be provided with fixing
arrangement and shall have an integral flushing rim of suitable type. It shall have an inlet for connecting the
flushing pipe of dimension confirming to IS 2556 and mentioned in Table No.2. The flushing rim may be box or
open rim type or a combination of both. In case of box rim, adequate number of holes and slot be provided. The
flushing rim and the inlet shall be of the self draining type and weep hole shall be provided at the flushing inlet
of the wall mounted water closet.
The WC shall be provided with not less than two fixing holes to enable the WC to be securely installed to
the wall using metallic corrosion resistant bolts and nuts and an independent concealed support frame. The
support frame (metal hanger or carrier), depending on the design shall be securely attached to the building
structural members so that no strain is transmitted to WC connector or any part of the plumbing system.
Each wall mounted water closet shall have an integral trap and P type outlet confirming to IS 2556 (Part
16): 2002 and mentioned in Fig. 25 & Fig. 26. Inside surface of water closet and trap shall be uniform and
smooth in order to ensure an efficient flushing. The outlet if without serration, shall be glazed and if same is
with serration, may not be glazed.

17.21.2 Marking
Each piece of wall mounted water closet shall be cleary and indelibly marked at a suitable place with the
following:-
(a) Name of trade mark of the manufacturer and
(b) Batch/lot numbers.
17.21.3 BIS certification marking

Wall mounted water closet shall be marked with the standard mark. The use of Standard Mark is governed
by the provisions of the Bureau of Indian Standards Act, 1986 and the Rules and Regulations made .
17.21.4 General requirement for installation of WC

The specification described in 17.2 shall be hold good so far as it is applicable.
17.21.4.1 All sanitary and plumbing work shall be carried out through licensed plumbers.
17.21.4.2 On completion of the work the site shall be cleaned and all rubbish disposed off as directed by the
Engineer-in-Charge.
17.21.5 Measurement
Wall mounted water closet shall be measured in numbers.
17.22 INSTALLATION OF FLOOR MOUNTED SINGLE PIECE WATER CLOSET (WC)

It shall consist of white vitreous China single piece, double traps syphonic water closet of approved
shape, brand, size, pattern and manufacturer with integrated white vitreous china cistern of capacity 10 ltr.
with dual flushing system, including all fitting and fixtures with seat cover, cistern fittings, nuts, bolts and
gasket etc. including making connection with the existing P/S trap, complete in all respect as per direction of
The general requirement relating to terminology, materials, manufacture, glazing, defects, minimum
thickness, tolerances, performance and methods of tests shall confirm to IS 2556 (Part-1).
Single piece floor mounted WC generally smaller than a two piece floor mounted WC. The flushing tank is
connected and sits lower on the bowl than on a two piece. Due to the smaller size, single piece WC are able
to be installed in toilet/bathroom with less square footage.
17.22.2 Fixing
The water closet shall be fixed to the floor by means of 75mm long and 6.5mm dia counter sunk bolts and
nuts embedded in the floor concrete.
17.22.2.3 Marking
Each piece of wall mounted water closet shall be cleary and indelibly marked at a suitable place with the
following:-
(a) Name of trade mark of the manufacturer and
(b) Batch/lot numbers.
17.22.3 General requirement for installation of WC

The specification described in 17.2 shall be hold good so far as they are applicable.
17.22.3.1 All sanitary and plumbing work shall be carried out through licensed plumbers.
17.22.3.2 On completion of the work the site shall be cleaned and all rubbish disposed off as directed by the
Engineer-in-Charge.
17.22.4 Measurement
Single piece floor mounted water closet shall be measured in numbers.

APPENDIX A
STANDARD WEIGHTS AND THICKNESS OF C.I. PIPES

(Clause 17.1.8)
For Sand Cast Iron Pipes IS 1729
Nominal dia of bore Thickness Over all weight of pipe
(mm) (mm) 1.5 m long (Kg) 1.80 m long (Kg) 2.0 m long (Kg)
50 5.0 9.56 11.41 12.65
75 5.0 13.83 16.52 18.37
100 5.0 18.14 21.67 24.15
150 5.0 26.70 31.92 35.66
For Cast Iron (Spun Pipes IS 3989).

Nominal dia Thickness Overall Weight in Kg. for an effective length in metres of
(mm) (mm) 3.000 2.500 2.000 1.800 1.500
50 3.5 13.40 11.3 9.2 8.4 7.1
75 3.5 20.0 16.8 13.8 12.5 10.6
100 4.0 30.0 25.5 21.0 18.8 16.0
150 5.0 56.0 47.0 38.5 34.9 29.5
Tolerances
(a) Tolerances on the external diameter of the barrel, the internal diameter of the socket and the
depth of socket shall be as follows:—
Dimensions (mm) Nominal Diameter (mm) Tolerance
External diameter of barrel 50, 75 ± 3.0
100 ± 3.5
150 ± 4.0
Internal diameter of socket All diameters ± 3.0
Depth of socket All diameters 10.0
The maximum and minimum jointing space resulting from these tolerances shall be such that the
jointing of the pipes and fittings is not adversely affected.
The tolerance on length of pipes shall be ± 20 mm.
(b) The tolerances on dimensions of fittings shall be as given below:
Type of Casting Dimension Tolerance mm

Bend pipes a +25 -10
b +20 -10
Branches with equal branch pipes a +25 -10
b +25 -10
Branches with unequal branch pipes L +30 -20
S. Shape casting L +50 -10
Taper collars L +25 -10
Other L +20 -10
Note:
(1) Tolerance on wall-thickness shall be limited to –15 per cent. No limits for plus tolerance is
specified.
(2) Tolerance for dimensions other than those specified above shall be as specified in IS 5519.
(3) Tolerance on mass shall be limited to –10 per cent. No limit for plus tolerance specified.

APPENDIX B
(Clause 17.1.8A)
DRAWING AND DIMENSIONS FOR STAINLESS STEEL SHIELDED COUPLING
A-1 Profile of EPDM rubber gasket as given inTable-6.
A-2 Design of stainless steel shield and clamp as given in Table-7.
Table- 6 EPDM Rubber Gasket

(Clause A-1)
Sl DN Outside Dia (D) Thickness (I) Height (H)

No. mm Mm Mm mm
(1) (2) (3) (4) (5)
i) 50 59.8 2.4 54
ii) 75 84.8 2.4 54
iii) 100 111.0 2.5 54
iv) 150 162.0 3.0 76
v) 200 211.0 3.0 101
A-3.2 Firmly seat the pipe or fitting ends against the integrally moulded center stop inside the
EPDM rubbergasket.
A-3.3 Slide the stainless steel shield and clampassembly over the EPDM rubber gasket and
tightenthe bands. For larger diameters couplings which havefour bands, the inner bands should be
tightened first and then the outer bands.
A-3.4 In all the cases, when tightening bands theyshould be tightened alternately to insure
that thecoupling shield is drawn up uniformly.
NOTE — Other types of joints can also be used at the discretion ofthe customer. The details given in
this Annex is for guidance only

Table-7 Stainless Steel Shield
(Clause A-2)
For Size DN50, DN75, DN100 For Size DN50, DN75, DN100
DN Height (H)
Sl. No.
mm mm
(1) (2) (3)
i) 50 54
ii) 75 54
iii) 100 54
iv) 150 76
v) 200 101

PIPE SYSTEMS AND PARTS
Sub Head : Sanitary Installations
Clause : 17.1

Fig. 17.1 : Pipe Systems and Parts
PIPE SYSTEMS AND PARTS

Clause : 17.1

Fig. 17.2 : Pipe Systems and Parts

FLUSHING CISTERNS
Clause : 17.1.1

Fig. 17.3 : Flushing Cisterns

FOOT REST
Clause : 17.1.3

Fig. 17.4 : Foot Rest

M.S. STAYS AND CLAMP
Clause : 17.1.6

Fig. 17.5 : M.S. Stays and Clamp

PLASTIC SEAT AND COVER

Clause : 17.1.9
Table 1 Dimensions of Seats and Covers

All dimensions in millimeters
Sl.No Description Dimensions

Min Max
(1) (2) (3) (4)
(i) Distance from centre line of hinge bolts to extreme 445 475
edge of rim at front, A
(ii) Length of opening at longest point, B 250 290
(iii) Width of opening at widest point, C 215 240
(iv) Overall width at widest point, D 380 -
(v) Distance between inner and outer rims, E 55 -
(vi) Centre-to-centre distance of seat bolt holes, F 145 175
(vii) Distance from centre line of hinge bolts to inner rim 85 -
of seat at the back, G
(viii) Thickness of seat at thinnest point 3 -
(ix) Thickness of cover at thinnest point 3 1
Note : Some hinging devices are made so as to provide adjustment in the longitudinal direction. This is
not precluded by these figures.
Fig. 17.6 : Plastic Seat and Cover

KITCHEN & LABORATORY SINKS

Clause : 17.1.10
Pattern Size A B C D
(1) (2) (3) (4) (5) (6)
(a) Kitchen sinks 750 x 450 x 250 750 450 250 150
(White glazed fire 600 x 450 x 250 600 450 250 150
clay) 600 x 450 x 200 600 450 200 150
(b) Kitchen sink with 510x1040x250 510 1040 250 150

drain board stainless 510x1040x225 510 1040 225 150
steel 510x1040x200 510 1040 200 150
510x1040x178 510 1040 178 150
( c )Kitchen sink 610x510x200 610 510 200 150

without drain board 610x460x200 610 460 200 150
stainless steel 470x420x178 470 420 178 150
(d) Laboratory sinks 600 x 400 x 200 600 450 200 90

500 x 350 x 150 600 350 150 90
450 x 300 x 150 450 300 150 90
400 x 250 x 150 400 250 150 90
Fig. 17.7 : Kitchen & Laboratory Sinks

WASTE FITTINGS FOR W.B. & SINKS

Clause : 17.1.15

No. and Sizes of Holes Indicative
Fig. 17.8 : Waste Fittings for W.B. & Sinks

URINAL BOWL TYPE
Clause : 17.1.13
Note : Where a closed channel with overflow is not provided a domed grating with perforating starting from the base
and the crown of which shall be 25 mm, minimum above surface shall be provided which may be integral or
otherwise.
BOWL PATTERN URINAL (FLAT BACK)
All dimensions in millimetres
Fig. 17.9 : Urinal Bowl Type

URINAL BOWL TYPE (Contd.)

Clause : 17.1.13
Note : Ovality of 5 percent is permissible on inlet and outlet diameters.

All Dimensions in Millimetres
Fig. 17.10 : Urinal Bowl Type (Corner Wall Type)

URINAL – HALF STALL
Chapter : Sanitary Installations

Clause : 17.1.13.2
BOWL TYPE FLAT BACK URINAL WITHOUT RIM
FUNCTIONAL DIMENSIONS OF BOWL PATTERN URINALS

Sl. No. Pattern Dimension

Height Projection Width Distance
H P W K, Min
1. Flat back with flushing rim
Size 1 440 265 355 140
Size 2 440 265 315 140
2. Flat back without flushing rim
Size 1 410 265 305 100
Size 2 590 375 390 100
3. Angle back with flushing rim 345 420 270 190
4. Angle back without flushing rim
Size 1
450 350 275 100
Size 2
580 500 300 100
CONNECTING DIMENSIONS OF BOWL PATTERN URINALS

Sl.No . Pattern Dimension in mm
a b c1 c2 d e1 e2 f, Min
1)
1. Flat back, with flushing rim — 20 ± 3 40 ± 5 50 ± 5 — 35 ± 2 55 20

2. Flat back, without flushing rim 75 20 ± 3 — 100 Min 65 ± 5 45 ± 2 60 Min 20
Max
3. Angle back, with flushing rim — 20 ± 3 35 ± 5 65 ± 5 — 35 ± 2 55 20
4. Angle back, without flushing rim 75 20 ± 3 — 150 65 ± 5 45 ± 2 60 20
max (for size 1)
225
(for size 2)
Explanation for Legends Used
a = Dimension from top of bowl to centre of water supply hole or spreade
b = Diameter of water supply hole
c1 = Distance from centre of water supply hole to back of bowl
c2 = Distance from centre of waste outlet to back of bowl
d = Dimension of outlet of the waste flange
e1 = Internal diameter of waste outlet
e2 = Outside diameter of the outlet hole
f = Depth of waste outlet
Note : Distance between pairs of screw holes for flat back with flushing rim bowl urinal shall be 395 mm for top/bottom fixing arrangement and 320 mm for side
fixing arrangement.
(1) Ovality is permissible within the variation allowed for the dimensions
(2) Ovality is permissible within ± 2 mm of the dimensions.
Fig. 17.11 : Urinal – Half Stall

URINAL SQUATTING PLATE

Clause : 17.1.13.4
SQUATTING PLATE URINAL
FUNCTIONAL DIMENSIONS OF SQUATTING PLATES (IN MM)
Sl.No. Description Ref. in Fig. above Size 1 Size 2

1. Size — 450 x 350 600 x 350
2. Length L 450 600
3. Minimum foot rest width W1 125 165
4. Width W 350 350
5. Height at back end H1 100 100
6. Height at front end H2 85 85
H
7. Minimum height at bowl draining surface 3 50 50
8. Width at flat top W2 100 100
9. Radius of curvature of the bowl R 65 65
Angle of direction of the two end spray hole with
10. that of the central one Ø 30° 30°
CONNECTING DIMENSIONS OF SQUATTING PLATES, MM
Description Ref. in Fig. above Size 1/Size 2

d
Diameter of inlet hole 1 40
Diameter of the inlet socket d2 50
Depth of the inlet socket, Min e 25
1) Ovality is permissible within the variation allowed for the dimensions.
Fig. 17.12 : Urinal Squatting Plate

SPREADER FOR URINAL

Clause : 17.1.13

Fig. 17.13 : Spreader for Urinal

WASH BASINS
Clause : 17.1.14

Fig. 17.14 : Wash Basins

FIXING ARRANGEMENT OF WASH BASIN
(ELEVATION OF WASH BASIN)

Clause : 17.1.14
Note : Stud shall be provided for supports intended for glazed earthenware, vitreoware wash basins only.
Fig. 17.15 : Fixing Arrangement of Wash Basin

TYPICAL VERTICAL SECTION OF WASH BASIN
(WASTE PIPE OPEN TO VIEW)

Clause : 17.1.14

Fig. 17.16 : Typical Vertical Section of Wash Basin (Waste Pipe Open to View)

TYPICAL VERTICAL SECTION OF WASH BASIN
(WASTE PIPE CONCEALED FROM VIEW)

Clause : 17.1.14

Fig. 17.17 : Typical Vertical Section of Wash Basin (Waste Pipe Concealed from View)

ANGLE BACK WASH BASIN
(PATTERN-2)

Clause : 17.1.14
Notes :
(1) Tap hole provisions are not shown. However provision shall be made for 1 or 2 Tap holes in any suitable position.
(2) Stud provisions are not shown but suitable provision shall be made for fixing purposes.
(3) Provision of soap recess need not be central in the case of single tap hole.
(4) Drawing not to scale.
(5) All dimensions are in mm.
Fig. 17.18 : Angle Back Wash Basin (Pattern-2)

LONG PATTERN SQUATTING PAN, TYPE I
Clause : 17.1.16.1
Functional Dimensions of Long and Orissa Pattern

All Dimensions in millimetres
Fig. 17.19 : Long Pattern Squatting Pan, Type I

ORISSA PATTERN SQUATTING PAN

Clause : 17.1.16.1
Note : Footrest may be flushed or raised, clearance permissible between raised footrest and rim opening.
All Dimensions in Milliletres.
Fig. 17.20 : Orissa Pattern Squatting Pan

INTEGRATED SQUATTING PAN

Clause : 17.1.16.1
Fig. 17.21 : Integrated Squatting Pan

PATTERN 1 AND PATTERN 2 WATER CLOSETS

Clause : 17.1.16.2

Fig. 17.22 : Pattern 1 and Pattern 2 Water Closets

PATTERN 3 WATER CLOSET WITH HORIZONTAL P-TRAP

Clause : 17.1.16.2
FUNCTIONAL DIMENSIONS
Fig. 17.23 : Pattern-3 Water Closet with Horizontal P-Trap

TYPICAL COUPLING JOINT INSTALLATON

Clause : 17.1.8A
Fig. 17.24 Typical coupling joint-installation

TYPICAL ILLUSTRATION OF WALL MOUNTED WATER CLOSET WITH CONCEALED
OUTLET (PATTERN 1)
Sub Head : 17.0 Sanitary Installations
Clause : 17.21.1
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TYPICAL ILLUSTRATION OF WATER CLOSET WITH FIXING ARRANGEMENT ON TOP OF
BRACKET (PATTERN 2)
Sub Head : 17.0 Sanitary Installations
Clause : 17.21.1

&ŝŐ17.26 Typical illustration of water closet with fixing arrangement on top of bracket (pattern 2)

SUB HEAD : 18.0
WATER SUPPLY
941
CONTENTS
18.2 General Requirements 950
18.3 Materials 952
18.3.1 Ball Valve (Brass) 953
18.3.2 Bib Taps and Stop Valve 953
18.3.3 Ferrules 954
18.3.4 Fire Hydrants 954
18.3.5 Gate Valve-Gun Metal 954
18.3.6 Pig Lead 954
18.3.7 Lead Wool 954
18.3.8 Non-return Valve-Gun Metal 954
18.3.9 Pipes and Specials 954
18.3.10 Pipes-Centrifugally Cast (Spun) Iron Pipes 955
18.3.11 Pipes-Galvanized Iron 955
18.3.12 Shower Rose Brass 956
18.3.13 Sluice Valves-Brass/Gun Metal 956
18.3.14 Surface Box 956
18.3.15 Water Meter (Domestic Type) 956
18.3.16 Yarn (Spun) 959
18.4 Laying and Jointing of Pipes and Fittings 959
18.4.1 Unloading 959
943 SUB HEAD 18.0 : WATER SUPPLY

18.4.2 Storing 959
18.4.3 Cutting 959
18.4.4 Trenches 960
18.4.5 Laying 961
18.4.6 Thrust Blocks 961
18.4.7 Back Filling and Tamping 962
18.4.8 Hydrostatic Tests 962
18.5 Laying and Jointing of Cast Iron Pipes and Fittings 963
(External Work)
18.6 Laying and Jointing of G.I. Pipes (External Work) 966
18.7 Laying and Jointing of G.I. Pipes (Internal Work) 967
18.8 Polypropylene Random Co-Polymer (PP-R) Pipes 968
18.9 Chlorinated Polyvinyl Chloride (CPVC) Pipes 972
18.10 PE-AL-PE Pipes 976
18.11 Making Connection of G.I., Distribution Branch with 980

G.I. (Main)
18. 12 Fixing Brass and Gun Metal Water Fittings 981
18.13 Fixing Ferrules 981
18.14 Installation of Fire Hydrant 981
18.15 Installation of Sluice Valve 981
18.16 Installation of Water Meter and Stop Valve 982
18.17 Fixing Surface Box 982
18.18 Polyethylene Water Storage Tanks 982
18.19 Tube Wells with Hand Pumps 984

18.20 Cutting Holes in Wall upto 30 x 30 cm 984
18.21 Cutting Holes in R.C.C. Floors (upto 15 x 15 cm) 984
18.22 Cutting Chases in Masonry Walls 985
18.23 CP Brass Bib Cock 986
18.24 CP Brass Long Nose Bib Cock 986
18.25 CP Brass Long Body Bib Cock 986
18.26 CP Brass Stop Cock (Concealed) 986
18.27 CP Brass Angle Value 986
18.28 CP Brass Extension Nipple 987
18.29 PTMT Bib Cock 987
18.30 PTMT Stop Cock 987
18.31 PTMT Pillar Cock 987
18.32 PTMT Push Cock 987
18.33 PTMT Grating 987
18.34 PTMT Ball Cock 987
18.35 PTMT Angle Stop Cock 987
18.36 PVC Connection Pipe 987
18.37 PTMT Extension Nipple for Water Tank Pipe 988
18.38 Disinfecting C.I Water Mains by Flushing with Water 988
18.39 Chrome Plated Brass Battery based Infrared Sensor 988

Operated Pillar Cock
Appendix A Tolerances for Cast Iron (Centrifugally Cast) Pipes 989
Appendix B Tolerances for Specials of Cast Iron Pipes 990
Appendix C Particulars of Medium Grade G.I. Pipes 991

Appendix D Procedure for Pressure Test 992
Appendix E Guidelines for Storage and Installation of CPVC Pipes 993
Appendix F Sampling and Criteria for Conformity of CPVC Pipes 994
Fig. 18.1 Ball Valve (Assembly) 999
Fig. 18.2 Fittings and Specials 1000
Fig. 18.3 Bib Tap & Stop Valve 1001
Fig. 18.4 Cocks Valves and Meter 1002
Fig. 18.5 Underground Fire Hydrant, Sluice-Valve Gate 1003
Fig. 18.6 Masonry Chambers and Surface Boxes 1004

(for Fire Hydrant and Water Meter)
Fig. 18.7 Masonry Chambers and Surface Boxes 1005

(for Stop Cock and Sluice Valves)
Fig. 18.8 Thrust Blocks 1006
Fig. 18.9 Hydrostatic Tests (End Closure for Pipes) 1007


1 IS 554 Pipe threads where pressure tight joints are required on the
threads- Dimensions, tolerances and designation.
2 IS 778 Specification for copper alloy gate, and check valves for water works
purposes
3 IS 779 Water meters (domestic type) -Specification
4 IS 14846 Specification for sluice valves for water works purposes (50 to 1200
mm size)
5 IS 781 Specification for cast copper alloy screw down bib taps and stop
valves for water services
6 IS 782 Specification for caulking lead
7 IS 909 Underground fire hydrant, sluice valve type-Specification
8 IS 1239 (Part 1) Steel tubes tubular and other wrought steel fittings, Part 1- Steel
tubes- Specification
9 IS 1239 (Part 2) Specification for mild steel tubes tubular and other wrought steel
fittings, Part 2-Mild street tubular and other wrought steel pipe
fittings
10 IS 1536 Centrifugally cast (spun) iron pressure pipes for water gas and
sewage- Specification
11 IS 1537 Specification for vertically cast iron pressure pipes for water, gas
and sewage
12 IS 1538 Cast iron fittings for pressure pipes for water, gas and sewage -
Specification
13 IS 1703 Water fittings - copper alloy float valves (horizontal plunger type)
- Specification
14 IS 2692 Ferrules for water services- Specification
15 IS 3950 Specification for surface boxes for sluice valves
16 IS 4736 Specification for Hot-dip Zinc Coatings on mild steel tubes
17 IS 5312 (Part 1) Swing type reflex (non return) valves for water works purposes.
Part 1- Single door pattern
18 IS 5312 (Part 2) Swing type reflex (non return) valves for water works purposes.
Part 2- Multi door pattern
19 IS 5382 Rubber sealing rings for gas mains, water mains and sewers
20 IS 9762 Specification for polyethylene floats (spherical) for float valves
21 IS 9763 Plastic Bib taps and stop valves (rising spindle) for cold water
services- specifications
22 IS 15450 PE-AL-PE Pipes for hot and cold water supplies-Specifications

23 IS 15778 Chlorinated Polyvinyl Chloride (CPVC) pipes for potable hot and
cold water distribution supplies-specifications.
24 IS 15801 Polypropylene- Random Copolymer Pipes for hot and cold
water supplies-Specifications
25 IS 2685 Code for selection/Installation and Maintenance of Sluice Valve

18.0 WATER SUPPLY
18.1 TERMINOLOGY
Air Gap: The unobstructed vertical distance through the free atmosphere between the lowest opening
from any pipe or fitting supplying water to a tank or other device and the flood level rim of the
receptacle in a water supply system.
Air Valve: A valve that releases air from a pipe line automatically without loss of water, or introduces
air into a pipe line automatically if the internal pressure becomes less than that of the atmosphere.
Available Head: The head of water available at the point of consideration due to main’s pressure or
overhead tank or any other source of pressure.
Back Flow: The flow of water into the distributing pipes of water system from any source or sources
other than its intended source.
Back Siphonage: The flowing back of used, contaminated or polluted water from a plumbing fitting
or vessel into a water supply system due to a lowering of pressure in such system.
Ball Cock (Fig. 18.1): A faucet opened or closed by the fall or rise of a ball floating on the surface of
water.
Branch (Fig. 18.2): (i) A special form of cast iron pipe used for making connections to water mains. The
various types are called T, Y, T-Y, double Y, and V branches, according to their respective shapes.
(ii) Any part of a piping system other than a main.
Capacity: The storage capacity of storage or flushing cistern or a tank when filled up to the water line.
Non Return Valve (Fig. 18.4): A device provided with a disc hinged on one edge so that it opens in
the direction of normal flow and closes with reversal of flow.
Collar: A pipe fitting in the form of a sleeve for jointing the spigot ends of two pipes in the same
alignment.
Coupling: A pipe fitting with inside threads only, used for connecting two pieces of pipe.
Cross (Fig. 18.2): A pipe fitting used for connecting four pipes at right angles.
Elbow (Fig. 18.2): A pipe fitting for providing a sharp change of direction in a pipe line.
Ferrule (Fig. 18.2): A pipe fitting for connecting a service pipe to a water main.
Fitting: Anything fitted or fixed in connection with the supply, measurement, control, distribution,
utilization or disposal of water.
Fire Hydrant (Fig. 18.5): A device connected to a water main and provided with necessary valve
and outlets, to which a fire hose may be attached for discharging water at a high rate for the purpose
of extinguishing fires, washing down streets, or flushing out the water main.
Flange (Fig. 18.2): A projecting flat rim on the end of a valve, pipe etc.

Flanged Pipe (Fig. 18.2): A pipe provided with flanges so that the ends can be joined together by
means of bolts.
Float Valve: A valve in which the closure to an opening such as a plug or gate is actuated by a float
to control the flow into a tank.
Sluice Valve (Gate Valve) (Fig. 18.4) : A valve in which the flow of water is cut off by means of a
circular disc., fitting against machine-smoothed faces, at right angles to the direction of flow. The
disc is raised or lowered by means of a threaded stem connected to the handle of the valve; the
opening in the valve is usually as large as the full bore of the pipe.
Nipple (Fig. 18.2): A tubular pipe fitting usually threaded on both ends and less than 300 mm long
used for connecting pipes or fittings.
Offset: A combination of elbows or bends which brings one section of the pipe out of line but into a
line parallel with the other section in a piping system.
Reflux Valve (Fig. 18.4): A non return valve used in a pipe line at a rising gradient to prevent water
that is ascending the gradient from flowing back in the event of a burst lower down.
Socket (Fig. 18.2): The female part of the spigot and socket joint.
Spigot (Fig. 18.2): The male part of a spigot and socket joint.
Stop Cock (Fig. 18.3): A control valve fixed at the end of a communication pipe which controls the
supply from the water main.
Storage Tank: A tank or a cistern for storage of water which is connected to the water main by
means of a supply pipe.
Service or Supply Pipe: Pipe through which supply is drawn from water mains.
Union (Fig. 18.2): A pipe fitting used for joining the ends of two pipes neither of which can be turned.
Valve: A device used for controlling the flow of water in a pipe line.
18.2 GENERAL REQUIREMENTS

18.2.1 Any damage caused to the building, or to electric, sanitary water supply or other installations
etc. therein either due to negligence on the part of the contractor, or due to actual requirements of
the work, shall be made good and the building or the installations shall be restored to its original
condition by the contractor. Nothing extra shall be paid for it, except where otherwise specified.
18.2.2 All water supply installation work shall be carried out through licensed plumbers.
18.2.3 It is most important to ensure that wholesome water supply provided for drinking and culinary
purposes, is in no way liable to contamination from any less satisfactory water. There shall, therefore,
be no cross connection whatsoever between a pipe or fitting for conveying or containing wholesome
water and a pipe or fitting for conveying or containing impure water or water liable to contamination
or of uncertain quality of water which has been used for any purpose. The provision of reflux or non-
return valves or closed and sealed valves shall not be construed a permissible substitute for complete
absence of cross-connection.

18.2.4 Where a supply of wholesome water is required as an alternative or standby to supply of less
satisfactory water or is required to be mixed with the latter, it shall be delivered only into a cistern,
and by a pipe or fitting discharging into the air gap at a height above the top edge of the cistern
equal to twice its nominal bore, and in no case less than 15 cm.
18.2.5 No piping shall be laid or fixed so as to pass into, through or adjoining any sewer, scour outlet
or drain or any manhole connected therewith nor through any ash pit or manure-pit or any material
of such nature that can cause undue deterioration of the pipe.
18.2.6 Where the laying of any pipe through fouled soil or previous material is unavoidable, the
piping shall be properly protected from contact with such soil or material by being carried through an
exterior cast iron tube or by some other suitable means. Any piping or fitting laid or fixed which does
not comply with the above requirements, shall be removed and re-laid in conformity with the above
requirements.
18.2.7 The design of the pipe work shall be such that there is no possibility of backflow towards the
source of supply from any cistern or appliance whether by siphonage or otherwise, and reflux or
non-return valves shall not be relied upon to prevent such back flow.
18.2.8 All pipe work shall be so designed, laid or fixed, and maintained so that it remains completely
watertight, thereby avoiding wastage of water, damage to property and the risk of contamination of
the water conveyed.
18.2.9 In designing and planning the layout of the pipe work, due attention shall be given to the
maximum rate of discharge, required economy in labour and materials, protection against damage
and corrosion, protection from frost, if required, and to avoidance of airlocks, noise transmission and
unsightly arrangement.
18.2.10 To reduce frictional losses, piping shall be as smooth as possible inside. Methods of jointing
shall be such as to avoid internal roughness and projection at the joints, whether of the jointing
materials or otherwise.
18.2.11 Change in diameter and in direction shall preferably be gradual rather than abrupt to avoid
undue loss of head. No bend or curve in piping shall be made so as to materially reduce or alter the
cross-section.
18.2.12 Underground piping shall be laid at such a depth that it is unlikely to be damaged by frost or
traffic loads and vibrations. It shall not be laid in ground liable to subsidence, but where such ground
cannot be avoided; special precautions shall be taken to avoid damage to the piping. Where piping
has to be laid across recently disturbed ground, the ground shall be thoroughly consolidated so as
to provide a continuous and even support.
18.2.13 Where the service pipe is of diameter less than 50 mm the stop valves shall be of the screw-
down type and shall have loose washer plates to act as non-return valves. Other stop valves in the
service line may be of the gate type.
18. 2.14 In flats and tenements supplied by a common service pipe a stop valve shall be fixed to
control the each branch separately. In large buildings a sufficient number of stop valves shall be
fixed on branch pipes, and to control groups of ball valves and draw off taps, so as to minimize
interruption of the supply during repairs, all such stop valves shall be fixed in accessible positions
and properly protected from being tampered with, they may be of the gate type to minimize loss of
head by friction.

18.2.15 Water for drinking or for culinary purposes as far as possible shall be on branch pipes
connected directly to the service pipe.
18.2.16 Pumps shall not be allowed on the service pipe as they cause a drop of pressure on the
suction side thereby affecting the supply to the adjoining properties. In cases where pumping is required,
a properly protected storage tank of adequate capacity shall be provided to feed the pump.
18.2.17 Service pipes shall be so designed and constructed as to avoid air-locks, so that all piping
and fittings above ground can be completely emptied of water to facilitate repairs. There shall be
draining taps or draw-off taps (not underground) at the lowest points, from which the piping shall rise
continuously to draw-off taps, ball valves, cisterns, or vents (where provided at the high points).
18.2.18 Service pipes shall be designed so as to reduce the production and transmission of noise as
much as possible. Appliances which create noise shall be installed as far distant as possible from the
living rooms of the house. High velocity of water in piping and fittings shall be avoided.Piping shall be
confined, as far as possible, to rooms where appliances are fixed, it shall have easy bends, and
where quietness is particularly desired, holder bats or clamps shall be insulated from the piping by
suitable pads.
18.2.19 The rising pipe to the storage cistern, if any, or to any feed cistern shall be taken as directly
as possible to the cistern and shall be fixed away from windows or ventilators.
18.2.20 All pipe work shall be planned so that the piping is accessible for inspection, replacement
and repair. To avoid its being unsightly, it is usually possible to arrange it in or adjacent to cupboards,
recesses, etc. provided there is sufficient space to work on the piping with the usual tools. Piping
shall not be buried in walls or solid floors. Where unavoidable, piping may be buried for short distances
provided that adequate protection is given against damage and that no joints are buried. If piping is
laid in ducts or chases, these shall be roomy enough to facilitate repairs and shall be so constructed
as to prevent the entry of vermin. To facilitate removal of pipe casing, floor boards covering piping
shall be fixed with screws or bolts.
18.2.21 When it is necessary for a pipe to pass through a wall or floor, a sleeve shall be fixed therein
for insertion of the pipe and to allow freedom for expansion, contraction and other movement. Piping
laid in wood floors shall, where possible, be parallel with the joists.
18.2.22 Where storage tanks are provided to meet overall requirements of water connection of
service pipe with any distributing pipe shall not be permitted except one direct connection for culinary
or drinking requirements.
18.2.23 No service pipe shall be connected to any water closet or urinal. All such supplies shall be
from flushing cisterns which shall have supply from storage tank.
18.2.24 No service or supply pipe shall be connected directly to any hot-water system or to any
apparatus used for heating other than through a feed cistern thereof.
18.3 MATERIALS
18.3.0 The standard size of brass or gun metal fittings shall be designated by the nominal bore of
the pipe outlet to which the fittings are attached. A sample of each kind of fittings shall be got approved
from the Engineer-in-Charge and all supplies made according to the approved samples.
All cast iron fittings shall be sound and free from laps, blow holes and pitting. Both internal and
external surfaces shall be clean, smooth and free from sand etc. Burning, plugging, stopping or

patching of the casting shall not be permissible. The bodies, bonnets, spindles and other parts shall
be truly machined so that when assembled the parts shall be axial, parallel and cylindrical with
surfaces smoothly finished. The area of the water way of the fittings shall not be less than area of the
nominal bore, chromium plating wherever specified shall be of 0.3 micron. The chromium shall never
be deposited on brass unless a heavy coating of nickel is interposed. In the case of iron a thick coat
of copper shall first be applied, then one of nickel and finally the chromium. In finish and appearance
the plated articles when inspected shall be free from plating defects such as blisters, pits roughness
and unplated areas and shall not be stained or discoloured. Before fitting is plated, the washer plate
shall be removed from the fittings, the gland packing shall be protected from the plating solution.
18.3.1 Ball Valve (Brass)

The ball valve shall be of Brass or Gunmetal as specified conforming to IS 1703 (Fig. 18.1). The
ball valve shall be of following two classes:—
(a) High Pressure: High pressure float valves are indicated by the abbreviation ‘HP’ and are
designed for use on mains having pressure of 0.175 MPa or above.
(b) Low Pressure: Low Pressure float valves are indicated by the abbreviation ‘LP’ and are
designed for use on mains having a pressure up to. 0.175 MPa.
The ball valves shall be of following nominal sizes 15 mm, 20 mm, 25 mm, 32 mm, 40 mm and
50 mm. The nominal size shall correspond with the nominal bore of the inlet shanks. Polyethylene
floats shall conform to IS 9762.
18.3.2 Bib Taps and Stop Valve

Brass (Fig. 18.3): A bib tap is a draw off tap with a horizontal inlet and free outlet and a stop valve
is a valve with suitable means of connections for insertion in a pipe line for controlling or stopping the
flow. They shall be of specified size and shall be of screw down type and shall conform to IS 781. The
closing device shall work by means of disc carrying a renewable non-metallic washer which shuts
against water pressure on a seating at right angles to the axis of the threaded spindle which operates
it. The handle shall be either crutch or butterfly type securely fixed to the spindle. Valve shall be of
the loose leather seated pattern. The cocks (taps) shall open in anti-clock wise direction.
The bib tap and stop valve shall be polished bright. The minimum finished weights of bib tap and
stop valve shall be as specified in Table 18.1.
TABLE 18.1
Minimum Finished Mass of Bib Taps and Stop Valves
Size Minimum Finished Mass
Bib Taps Internally Externally Mixed End
Threaded Threaded
(1) (2) (3) (4) (5)
mm kg kg kg kg
8 0.250 0.220 0.250 0.235
10 0.300 0.300 0.350 0.325
15 0.400 0.330 0.400 0.365
20 0.750 0.675 0.750 0.710
25 1.250 1.180 1.300 1.250
32 -- 1.680 1.800 1.750
40 -- 2.090 2.250 2.170
50 -- 3.700 3.850 3.750
In case these are required to be nickel plated, the plating shall be of the first quality with a good
thick deposit of silvery whiteness capable of taking high polish which will not easily tarnish or scale.

18.3.3 Ferrules (Fig. 18.2)
The ferrules for connection with C.I. main shall generally conform to IS 2692. It shall be of non
ferrous materials with a C.I. bell mouth cover and shall be of nominal bore as specified. The ferrule
shall be fitted with a screw and plug or valve capable of completely shutting off the water supply to
the communication pipe, if and when required.
18.3.4 Fire Hydrants (Fig. 18.5)

The hydrant shall conform to IS 909 and shall consist of the following components:
(a) Body (d) Gland (g) Valve
(b) Bonnet (e) Spindle Cap (h) Screwed Outlet
(c) Spindle (f) Spindle Nut (i) Outlet and Chain
The body, bonnet, gland, outlet cap and spindle cap and shall be of good quality cast iron grade
FG 200 of IS 210. Outlet, seat for valve, valve, spindle nut, check nut shall be made of copper alloy
as per IS 909.
18.3.5 Gate Valve - Gun Metal (Fig. 18.5)

These shall be of the gun metal fitted with wheel and shall be of gate valve type opening full way
and of the size as specified. These shall generally conform to IS 778.
18.3.6 Pig Lead

Pig lead shall be of uniform quality, clean and free from foreign materials. It shall be of uniform
softness and capable of being easily caulked or driven. It shall conform to IS 782 for caulking lead in
all respects.
18.3.7 Lead Wool

Lead wool shall conform to IS 782 in all respects. Lead wool shall consist of fine strands or plated
ribbons of lead. The cross-section of the individual strands shall be flat. The dimensions in the
sectional plane shall not be less than 0.13 mm and not more than 0.90 mm and the rope shall be
supplied in minimum lengths of two metres and the maximum length in any one package shall be
such that the package does not weigh more than 50 Kg.
18.3.8 Non-Return Valve (Gun Metal) (Fig. 18.4)

A non- return valve permits water to flow in one direction only and is provided on the ascending
part of the main to check return flow. The non-return valve shall be of Gun metal and shall be of
horizontal or vertical flow type as specified.
The valve shall be of quality approved by the Engineer-in-Charge and shall generally conform
to IS 778.
18.3.9 Pipes and Specials

Pipes and specials may be of any of the following types as specified:
(a) Cast iron centrifugally cast (spun) – IS 1536
(b) Galvanised steel – IS 1239 & IS 4736
(c) PE-AL-PE Pipes – IS 15450
(d) PP-R Pipes – IS 15801
(e) CPVC pipes – IS 15778
In choosing the material for piping and fittings, account shall be taken of the character of the
water to be conveyed through it, the nature of the ground in which the pipes are to be laid and the
relative economics.

18.3.10 Pipes- Centrifugally Cast (Spun) Iron Pipes
18.3.10.1 The spun iron pipes shall conform to IS 1536. The spun iron pipes shall be of cast iron cast
centrifugally and vary in diameters from 80 mm to 750 mm. These shall be of class LA, class A and
class B, as specified. Pipes shall be tested hydrostatically at the pressure specified in table 18.2 &
18.3. Tolerances on specified dimensions shall be as prescribed in Appendix A.
18.3.10.2 Specials: The specials shall conform to IS 1538. The hydraulic test pressure of each class
shall be as detailed in Table 18.4. Tolerances on specified dimensions shall be as prescribed in
Appendix B of sub head- 18.
TABLE 18.2
Hydrostatic Test pressure for centrifugally cast socket & spigot pipes in MPa
Hydrostatic Test pressure for works in MPa
Class Up to DN 600 DN 700 & above
LA 3.5 1.5
A 3.5 2.0
B 3.5 2.5
TABLE 18.3
Hydrostatic Test pressure for centrifugally cast pipes with screwed on flanges in MPa
Class Up to DN 600 DN 700 & above
B 2.5 1.6
TABLE 18.4
2
Hydrostatic Test pressure for fittings in MPa (N/mm ) (metre head)
Nominal - Diameter Fitting without branches or with Fitting with Branches greater
branches not greater than half than half the Principal
the principle diameter. Diameter.
Up to and including 300 mm 2.5 (25) 2.5 (25)
Over 300 mm and up to and
including 600 mm 2.0 (20) 2.0 (20)
Over 600 mm and up to and
including 1500 mm 1.5 (15) 1.0 (10)
18.3.11 Pipes-Galvanised Iron

18.3.11.1 The pipes (tubes) shall be galvanised mild steel hot finished seamless (HFS) or welded
(ERW) HRIW or HFW screwed and socketed conforming to the requirements of IS 1239 Part-I for
medium grade. They shall be of the diameter (nominal bore) specified in the description of the item,
the sockets shall be designated by the respective nominal bores of the pipes for which they are
intended.
18.3.11.2 Galvanising shall conform to IS 4736 : The zinc coating shall be uniform adherent,
reasonably smooth and free from such imperfections as flux, ash and dross inclusions, bare batches,
black spots, pimples, lumping runs, rust stains, bulky white deposits and blisters. The pipes and
sockets shall be cleanly finished, well galvanised in and out and free from cracks, surface flaws
laminations and other defects. All screw threads shall be clean and well cut. The ends shall be cut
cleanly and square with the axis of the tube.
18.3.11.3 The dimensions and weights of pipes and sockets and tolerances shall be as prescribed in
Appendix ‘C’.

18.3.11.4 All screwed tubes and sockets shall have pipe threads conforming to the requirements of
IS 554. Screwed tubes shall have taper threads while the sockets shall have parallel threads.
18.3.11.5 All tubes shall withstand a test pressure of 50 Kg/sq.cm without showing defects of any kind.
18.3.11.6 Fittings : The fittings shall be of mild steel tubular or wrought steel fittings conforming to IS
1239 (Part-2) or as specified. The fittings shall be designated by the respective nominal bores of the
pipes for which they are intended.
18.3.12 Shower Rose Brass

The shower rose shall be of chromium plated brass of specified diameter. It shall have uniform
perforations. The inlet size shall be 15 mm or 20 mm as required.
18.3.13 Sluice Valves-Brass/Gun Metal (Fig. 18.4)

The sluice valves are used in a pipe line for controlling or stopping flow of water. These shall be
of specified size and class and shall be of inside non-raising screw type up to 300 mm size and
raising or non-raising screw type above 300 mm with either double flange or double socket ends and
cap or hand wheel. These shall in all respects comply with the Indian Standard Specification IS
14846. Class I sluice valves are used for maximum working pressure of 10 Kg/sq.cm (100 metre
head) and class II sluice valve for 15 Kg/sq.cm (150 metre head).
The body, domes covers, wedge gate and stuffing box shall be of good quality cast iron, the
spindle of bronze, and the nut and valve seats of leaded tin bronze. The bodies, spindles and other
parts shall be truly machined with surface smoothly finished. The area of the water way of the fittings
shall be not less than the area equal to the nominal bore of the pipe.
The valve shall be marked with an arrow to show the direction of turn for closing of the valve.
18.3.14 Surface Box (Fig. 18.6 & 18.7)

This shall be of cast iron, well made and free from casting and other defects. All sharp edges
shall be removed and finished smooth. The shape and dimensions for surface boxes for stop cocks,
sluice valves, fire hydrants, water meters etc. shall be as specified in Fig. 18.3 & 18.4.
The C.I. surface boxes shall be coated with a black bituminous composition except in case of fire
hydrants where the cover of the surface box shall be painted with two coats of rust resisting bright
luminous yellow paint for clear visibility during night.
18.3.15 Water Meter (Domestic Type) (Fig. 18.4)

18.3.15.1 Water meters shall be selected according to flow to be measured and not necessarily to
suit a certain size of main. The following points shall govern the selection of meters:
(a) The maximum flow shall not exceed the nominal capacity of the meter.
(b) The continuous flow shall be not greater than the continuous running capacity rating.
(c) The minimum flow to be measured shall be within minimum starting flows.
18.3.15.2 Inferential water meter has the same accuracy as the semi -positive type at higher flows; it
passes unfiltered water better than a semi-positive meter and is lower in cost.
18.3.15.3 Special care is necessary in selecting the most suitable meter where large rates of flow
may exist for short periods. The normal working flow shall be well within the continuous running
capacity specified in IS 779, as high rates of flow over short period may cause excessive wear if the
meter chosen is too small for the duty.

18.3.15.4 Owing to the fine clearances in the working parts of meters, they are not suitable for
measuring water containing sand or similar foreign matter, and in such cases a filter or dirt box of
adequate effective area shall be fitted on the upstream side of the meter. See Fig. 18.4. It shall be
noted that the normal strainer fitted inside a meter is not a filter and does not prevent the entry of
small particles, such as sand.
18.3.15.5 Water meters and their parts, especially parts coming in continuous contact with water shall
be made of materials resistant to corrosion and shall be non -toxic and non-training. Use of dissimilar
metals in contact under water shall be avoided as for possible in order to minimise electrolytic corrosion.
18.3.15.6 Body : The body of water meter shall be made either from Type A or Type B materials as
specified below:—
Type A : The body of water meters shall be made from bronze, brass or any other corrosion resistant
material e.g. Grey iron castings, blackheart malleable iron, pherodial graphite iron casting.
Type B: The body of the water meters shall be made form suitable plastics.
Note: Plastics shall have following qualities:

(i) It shall not affect the potability of water.
(ii) Elongation, 15 per cent, Min. on a specimen of length 150 mm (for procedure of determination
of elongation).
(iii) Water absorption on immersion for 24 hours should not exceed 0.6 per cent by weight (for
procedure of determination of water absorption).
(iv) It shall be capable of withstanding temperature up to 55°C without undergoing deformation
or softening and becoming unsatisfactorily in performance.
18.3.15.7 Registration Box: Registration box of water meters of Type A shall be made from bronze,
brass, aluminium alloy or suitable plastics. Registration box of water meters of Type B shall be made
from suitable plastics or aluminium alloys. The registration box of dry dial water meters shall be
provided with one or two escape holes for minimising the accumulation of condensed water.
18.3.15.8 Cap: Cap of water meters of Type A shall be made from brass, bronze, aluminium alloy
or suitable plastics. The cap of water meters of Type B shall be made of plastics or aluminium
alloy. Where the cap and registration box are integral, the materials for cap may be the same as
used for registration box. The cap shall be so designed and fixed to the registration box as to
avoid entry of water and dirt. The transparent window which covers the dial shall be inserted
from the inside into the cap. The protective lid shall be secured by a robust hinge or other
suitable method of robust construction.
18.3.15.9 Locking Arrangement: Provision shall also be made to lock the lid. The provision shall be
such that the lock is conveniently operated from the top. Where the provision is designed for use in
conjunction with padlocks, the hole provided for padlocks shall be of a diameter not less than 4 mm.
18.3.15.10 Wiper: Where so required for dry-type water meters the transparent window covering
the dial shall be provided with a wiper on the inner side for wiping off condensed water.
18.3.15.11 Connecting Arrangements: The meter casing shall be fitted in the pipe line by means of
two conical or cylindrical nipples or tail pieces with connecting nuts which shall be provided with each
meter. The nipples of water meters of Type A shall be made of the same materials as specified for body.

Nipples of water meters of Type B shall be made of the same materials as specified for the body
where they are integral with the body of the water meters; where they are separate, they shall be
made of malleable iron, galvanized steel or suitable plastics. The nuts shall be of the same material
as used for nipples. The internal diameter of the nipple where it connects the pipe line shall be equal
to that corresponding to the nominal size of the meter. The threads on the connection shall conform
to IS 779. The minimum length of the threads shall be as given in Table 18.5.
18.3.15.12 Strainers: Water meters shall be provided with strainers. Strainers shall be of a material
which is not susceptible to electrolytic corrosion. They shall be of plastics or other corrosion-resistant
materials for both Type A and Type B meters. They shall be rigid, easy to remove and clean, and
shall be fitted on the inlet side of the water meter. It shall be possible to remove and clean the strainer
in such a way as not to permit disturbing the registration box or tampering with it. The strainer shall
have a total area of holes not less than twice the area of the nominal inlet bore of the pipe to which
the meter is connected however, in the case of meters provided with internal strainer involving opening
of the registration box for cleaning, an additional external strainer shall be fitted on the inlet side
satisfying the above requirements.
Overall dimension of water meters shall be as specified in Table 18.6.
TABLE 18.5
Minimum Length of Thread on Connections
Nominal size of meter Minimum length of thread

15 12
20 14
25 16
40 20
50 25
(All dimensions in millimeters)
Screws & studs shall be of brass or other corrosion resistant material.
TABLE 18.6
Overall Dimensions of Water Meters
Nominal size of Meter Overall length including Overall width. (Max.) Overall height (Max.)
nipples
1 2 3 4
15 250 100 180
20 290 130 240
25 380 170 260
40 430 210 300
50 470 270 300
All dimensions are in mm.
Tolerance on the overall length shall be ± 5 mm. for meter with nipples and +0,-2 mm for meters
without nipples.

18.3.15.13 Capacity on Short Period Rating or Nominal Capacity: The nominal capacity of the
water meters shall be as specified in Table 18.7. The meters shall be capable of giving minimum
discharges as stated in the table without the head loss exceeding 10 m within the meters.
18.3.16 Yarn (Spun)

Spun yarn shall be of clean hemp and of good quality. It shall be soaked in hot coal tar or bitumen
and cooled before use.
18.4 LAYING AND JOINTING OF PIPES AND FITTINGS
18.4.1 Unloading
18.4.1.1 The pipes shall be unloaded where they are required.
18.4.1.2 Unloading (except where mechanical handling facilities are available) : Pipes weighing
up to 60 kg shall be handled by two persons by hand passing. Heavier pipes shall be unloaded from
the lorry or wagon by holding them in loops, formed with ropes and sliding over planks set not
steeper than 45 degree. The planks shall be sufficiently rigid and two ropes shall always be used to
roll the pipes down the planks. The ropes should be tied on the side opposite the unloading. Only
one pipe shall be unloaded at a time.
TABLE 18.7
Nominal Capacity of Water Meters
Discharge per hour
Nominal size of meter Semi positive Type Inferential Type

(mm) (liters) (liters)
15 2000 2500
20 3400 3500
25 5500 5500
40 10000 16000
50 15000 23000
18.4.1.3 Under no circumstances shall the pipes be thrown down from the carriers or be dragged or rolled
along hard surfaces.
18.4.1.4 The pipes shall be checked for any visible damage (such as broken edges, cracking or spalling of
pipe) while unloading and shall be sorted out for reclamation. Any pipe which shows sufficient damage to
preclude it from being used shall be discarded.
18.4.2 Storing
18.4.2.1 The pipes and specials shall be handled with sufficient care to avoid damage to them. These shall be
lined up on one side of the alignment of the trench, socket facing upgrade when line runs uphill and upstream
when line runs on level ground.
18.4.2.2 Each stack shall contain pipes of same class and size, consignment or batch number and particulars
of suppliers, wherever possible, shall be marked on the stack.
18.4.2.3 Storage shall be done on firm, level and clean ground. Wedges shall be provided at the bottom layer
to keep the stack stable.
18.4.3 Cutting
18.4.3.1 Cutting of pipes may be necessary when pipes are to be laid in lengths shorter than the lengths
supplied, such as while replacing accessories like tees, bends, etc. at fixed position in the pipe lines.

18.4.3.2 A line shall be marked around the pipe with a chalk piece at the point where it is to be cut.
The line shall be so marked that the cut is truly at right angle to the longitudinal axis of the pipe. The
pipe shall be rigidly held on two parallel rafters nailed to cross beams, taking care that the portion to
be cut does not overhang and the cut mark is between the two rafters. The pipe shall be neatly cut at
the chalk mark with carpenter’s saw or hacksaw having a long blade, by slowly rotating the pipe
around its longitudinal axis so as to have the uncut portion on top for cutting. Cutting of the pipe at
the overhang should, as far as possible, be avoided, as an overhanging and is liable to tear off due
to its weight before the cutting is complete.
18.4.4 Trenches
18.4.4.1 The trenches shall be so dug that the pipes may be laid to the required alignment and at
required depth.
18.4.4.2 Cover shall be measured from top of pipe to the surface of the ground.
18.4.4.3 The bed of the trench, if in soft or made up earth, shall be well watered and rammed before
laying the pipes and the depressions, if any, shall be properly filled with earth and consolidated in 20
cm layers.
18.4.4.4 If the trench bottom is extremely hard or rocky or loose stony soil, the trench shall be
excavated at least 150 mm below the trench grade. Rocks, stone or other hard substances from the
bottom of the trench shall be removed and the trench brought back to the required grade by filling
with selected fine earth or sand (or fine moorum if fine soil or sand is not available locally) and
compacted so as to provide a smooth bedding for the pipe. Where excavation requires blasting
operation, it shall be ensured that no pipes have been stacked in the vicinity and completed pipe line
in the vicinity has already been covered before starting of blasting operations; this is necessary to
prevent damage to the exposed pipes in the vicinity by falling stones as a result of blasting.
18.4.4.5 After the excavation of the trench is completed, hollows shall be cut at the required position
to receive the socket of the pipes and these hollows shall be of sufficient depth to ensure that the
barrels of the pipes shall rest throughout their entire length on the solid ground and that sufficient
spaces left for jointing the underside of the pipe joint. These socket holes shall be refilled with sand
after jointing the pipe.
18.4.4.6 Roots of trees within a distance of about 0.5 metre from the side of the pipe line shall be
removed or killed.
18.4.4.7 The excavated materials shall not be placed within 1 metre or half of the depth of the trench,
whichever is greater, from the edge of the trench. The materials excavated shall be separated and
stacked so that in refilling they may be re-laid and compacted in the same order to the satisfaction of
18.4.4.8 The trench shall be kept free from water. Shoring and timbering shall be provided wherever
required. Excavation below water table shall be done after dewatering the trenches.
18.4.4.9 Where the pipe line or drain crosses an existing road, the road crossing shall be excavated
half at a time, the 2nd half being commenced after the pipes have been laid in the first half and the
trench refilled. Necessary safety measures for traffic as directed shall be adopted. All types, water
mains cables, etc. met within the course of excavation shall be carefully protected and supported.
Care shall be taken not to disturb the electrical and communication cable met with during course of
excavation, removal of which, if necessary, shall be arranged by the Engineer-in-Charge.

18.4.5 Laying
18.4.5.1 The pipes shall be lowered into the trench by means of suitable pulley blocks, sheer legs
chains ropes etc. In no case the pipes shall be rolled and dropped into the trench. One end of each
rope may be tied to a wooden or steel peg driven into the ground and the other end held by men
which when slowly released will lower the pipe into the trench. After lowering, the pipes shall be
arranged so that the spigot of one pipe is carefully centered into the socket of the next pipe, and
pushed to the full distance that it can go. The pipe line shall be laid to the levels required. Specials
shall also be laid in their proper position as stated above.
18.4.5.2 Where so directed, the pipes and specials may be laid on masonry or concrete pillars. The
pipe laid on the level ground, shall be laid with socket facing the direction of flow of water.
18.4.5.3 The pipes shall rest continuously on the bottom of the trench. The pipes shall not rest on
lumps of earth or on the joints. Four metre long wooden templates may be used to check the level of
the bed. Clearance of approximately 100 mm in depth and width equal to length of the collar plus
30mm on both sides shall be provided at the joint which shall be refilled from sides after the joint is
made.
18.4.5.4 In unstable soils, such as soft soils and dry lumpy soils it shall be checked whether the soils
can support the pipe lines and if required suitable special foundation shall be provided.
18.4.5.5 Some clayey soils (for example black cotton soil) are drastically affected by extremes of
saturation and dryness. In changing from saturated to a dry condition, these soils are subjected to
extraordinary shrinkage which is usually seen in the form of wide and deep cracks in the earth
surface and may result in damages to under ground structures, including pipe materials. The clay
forms a tight gripping bond with the pipe, subjecting it to excessive stresses as the clay shrinks. It is
recommended that in such cases an envelope of a minimum 100 mm of tamped sand shall be made
around the pipe line to avoid any bonding.
18.4.5.6 In places where rock is encountered, cushion of fine earth or sand shall be provided for a
depth of 150 mm by excavating extra depth of the trench, if necessary, and the pipes laid over the
cushion. Where the gradient of the bed slopes is more than 30 degree it may be necessary to anchor
a few pipes against sliding downwards (Fig. 18.8).
18.4.6 Thrust Blocks (Fig. 18.8)

18.4.6.0 Thrust blocks are required to transfer the resulting hydraulic thrust from the fitting of pipe
on to a larger load bearing soil section.
18.4.6.1 Thrust blocks shall be installed wherever there is a change in the direction/size of the pipe
line or the pressure line diagram, or when the pipe line ends at a dead end. If necessary, thrust
blocks may be constructed at valves also.
18.4.6.2 Thrust blocks shall be constructed taking into account the pipe size, water pressure, type of
fitting, gravity component when laid on slopes and the type of soil. The location of thrust blocks for
various types’ fittings is given in Fig. 18.8.
18.4.6.3 When a fitting is used to make a vertical bend, it shall be anchored to a concrete thrust
block designed to have enough weight to resist the upward and outward thrust. Similarly at joints,
deflected in vertical plane, it shall be ensured that the weight of the pipe, the water in the pipe and
the weight of the soil over the pipe provide resistance to upward movement. If it is not enough, ballast
or concrete shall be placed around the pipe in sufficient weight to counteract the thrust.

18.4.6.4 When the line is under pressure there is an outward thrust at each coupling. Good soil,
properly tamped is usually sufficient to hold pipe from side movement. However, if soft soil
conditions are encountered, it may be necessary to provide side thrust blocks of other means of
anchoring. In such cases only pipe on each side of the deflected coupling shall be anchored
without restricting the coupling.
18.4.6.5 Pipes on slopes need be anchored only when there is a possibility of the back fill around the
pipe sloping down the hill and carrying the pipe with it. Generally for slopes up to 30 degree good
well drained soil carefully tamped in layers of 100 mm under and over the pipe, right up to the top of
trench will not require anchoring.
18.4.6.6 For steeper slopes, one out of every three pipes shall be held by straps fastened to vertical
supports anchored in concrete.
18.4.7 Back Filling and Tamping

18.4.7.1 Back filling shall follow pipe installation as closely as possible to protect pipe from falling
boulders, eliminating possibility of lifting of the pipe due to flooding of open trench and shifting pipe
out of line by caved in soil.
18.4.7.2 The soil under the pipe and coupling shall be solidly tamped to provide firm and continuous
support for the pipe line. Tamping shall be done either by tamping bars or by using water to consolidate
the back fill materials.
18.4.7.3 The initial back fill material used shall be free of large stones and dry lumps. In stony areas
the material for initial back fill can be shaved from the sides of the trenches. In bogs and marshes,
the excavated material is usually little more than vegetable matter and this should not be used for
bedding purposes. In such cases, gravel or crushed stone shall be hauled in.
18.4.7.4 The initial back fill shall be placed evenly in a layer of about 100 mm thick. This shall be
properly consolidated and this shall be continued till there is a cushion of at least 300 mm of cover
over the pipe.
18.4.7.5 If it is desired to observe the joint or coupling during the testing of mains they shall be left
exposed. Sufficient back fill shall be placed on the pipe to resist the movement due to pressure
while testing.
18.4.7.6 Balance of the back fill need not be so carefully selected as the initial material. However,
care shall be taken to avoid back filling with large stones which might damage the pipe when spaded
into the trench.
18.4.7.7 Pipes in trenches on a slope shall have extra attention to make certain that the newly
placed back fill will not become a blind drain in effect because until back fill becomes completely
consolidated there is a tendency for ground or surface water to move along this looser soil resulting
in a loss of support to the pipe. In such cases, the back fill shall be tamped with extra care and the
tamping continued in 100 mm layers right up to the ground level.
18.4.8 Hydrostatic Tests (Fig. 18.9)

18.4.8.1 After a new pipe has been laid, jointed and back filled (or any valved section thereof), it
shall be subjected to the following two tests:
(a) Pressure test at a pressure of at least double the maximum working pressure-pipe and
joints shall be absolutely water tight under the test.
(b) Leakage test (to be conducted after the satisfactory completion of the pressure test) at a
pressure to be specified by the authority for duration of two hours.

18.4.8.2 Hydrostatic Tests: The portions of the line shall be tested by subjecting to pressure test as
the laying progresses before the entire line is completed. In this way any error of workmanship will be
found immediately and can be corrected at a minimum cost. Usually the length of the section to be
tested shall not exceed 500 m.
18.4.8.3 Where any section of a main is provided with concrete thrust blocks or anchorages, the
pressure test shall not be made until at least five days have elapsed after the concrete is cast. If
rapid hardening cement has been used in these blocks or anchorages, test shall not be made until at
least two days have elapsed.
18.4.8.4 Prior to testing, enough back fill as described in 18.4.7 shall be placed over the pipe line to
resist upward thrust. All thrust blocks forming part of the finished line shall have been sufficiently
cured and no temporary bracing shall be used.
18.4.8.5 The open end of the section shall be sealed temporarily with an end cap having an outlet
which can serve as an air relief vent or for filling the line, as may be required. The blind face of the
end cap shall be properly braced during testing by screw jacks and wooden planks or steel plate as
shown in Fig. 18.6.
18.4.8.6 The section of the line to be tested shall be filled with water manually or by a low pressure
pump. Air shall be vented from all high spots in the pipe line before making the pressure strength test
because entrapped air gets compressed and causes difficulty in raising the required pressure for
the pressure strength test.
18.4.8.7 The test pressure shall be gradually raised at the rate of approximately one Kg./sq. cm./
min. The duration of the test period if not specified shall be sufficient to make a careful check on the
pipe line section.
18.5 LAYING AND JOINTING OF CAST IRON PIPES AND FITTINGS (EXTERNAL WORK)
18.5.0 Specifications described in 18.4 shall apply, as far as applicable.
TABLE 18.8
Test Pressure for Pipes
Class of pipe Maximum field test pressure kgf./sq.cm
5 3.75
10 7.50
15 11.25
20 15.00
25 18.75
18.5.1 Trenches
18.5.1.1 The gradient is to be set out by means of boning rods and the required depth to be excavated
at any point of the trench shall be regarded as directed by the Engineer -in-Charge. The depth of the
trench shall not be less than 1 metre measured from the top of the pipe to the surface of the ground
under roads and not less than 0.75 metre elsewhere.
18.5.1.2 The width of the trench shall be the nominal diameter of the pipe plus 40 cm but it shall
not be less than 55 cm in case of all kinds of soils excluding rock and not less than 1 metre in case
of rock.

18.5.2 Laying
Any deviation either in plan or elevation less than 11.25 degrees shall be effected by laying the
straight pipes around a flat curve of such radius that minimum thickness of lead at the face of the
socket shall not be reduced below 6 mm or the opening between spigot and socket increased beyond
12 mm at any joint. A deviation of about 2.25 degree can be effected at each joint in this way. At the
end of each day’s work the last pipe laid shall have its open ends securely closed with a wooden plug
to prevent entry of water, soil, rats and any other foreign matter into the pipe.
18.5.3 Lead Caulked Joints with Pig Lead

18.5.3.1 This type of lead caulking is generally done in providing joints in gas water and sewer lines
wherever it is practicable to use cast lead caulking, but not in case of wet conditions.
18.5.3.2 The approximate depth and weights of pig lead for various diameters of C.I. pipes and
specials shall be as given in Table 18.9.
TABLE 18.9
Lead for Different Sizes of Pipes
Nominal size of pipe Lead per joint Depth of lead joint
(mm) (Kg.) (mm)
(1) (2) (3)
80 1.8 45
100 2.2 45
125 2.6 45
150 3.4 50
200 5.0 50
250 6.1 50
300 7.2 55
350 8.4 55
400 9.5 55
450 14.0 55
500 15.0 60
600 19.0 60
700 22.0 60
750 25.0 60
Note: 1. The quantity of lead given in the table is on average basis and a variation of 10 per
cent is permissible.
2. Before pipes are jointed on large scale, three or four sample joints shall be made and the
average consumption of lead per joint shall be got approved by the Engineer-in-Charge.
Only required quantity of spun yarn shall be put so as to give the specified depth of lead in the joint.
18.5.4 Lead Caulked Joint with Lead Wool Yarn

18.5.4.1 This type of lead caulking is generally done when it is inconvenient or dangerous to use
molten lead for joints, for example in cases such as inverted joints or in wet trenches or in exceptional
cases. In such cases the joints shall be made with lead wool or yarn. Caulking with lead wool or yarn
shall however be not carried out without the prior permission of Engineer-in-Charge.
18.5.4.2 The approximate weights and depths of lead wool or lead yarn required for each joint of
various dia. of C.I. pipes and specials shall be as given in Table 18.10. Just sufficient quantity of spun
yarn shall be put so as to give specified depth of lead wool.

18.5.4.3 Jointing: The spun yarn shall first be inserted and caulked into the socket as described
under jointing with pig lead. Lead wool or yarn shall then be introduced in the joint in strings not less
than 6 mm thick and the caulking shall be repeated with each turn of lead wool or yarn. The whole of
the lead wool or yarn shall be compressed into a dense mass. The joint shall then be finally finished
flush with face of the socket.
18.5.5 Flanged joints

18.5.5.1 Cast iron pipes may be jointed by means of flanges cast on. The jointing material used
between flanges of pipes shall be compressed fiber board or rubber of thickness between 1.5 mm to
3 mm. The fiber board shall be impregnated with chemically neutral mineral oil and shall have a
smooth and hard surface. Its weight per m2 shall be not less than 112 gm/mm thickness.
TABLE 18.10
Diameter of pipe Weight of lead wool or lead yarn Depth of lead wool or lead yarn
(mm) (kg) (mm)
80 0.80 19
100 0.90 19
125 1.25 20
150 1.60 23
200 2.05 23
250 2.95 25
300 3.50 25
350 4.65 29
400 5.70 31
450 6.70 32
500 8.30 33
600 10.00 35
700 11.80 36
750 13.60 38
800 15.40 40
900 16.80 40
Note: An allowance of five per cent variation in the specified weights and depths is permissible.
18.5.5.2 Each bolt should be tightened a little at a time taking care to tighten diametrically opposite
bolts alternatively. The practice of fully tightening the bolts one after another shall not be allowed.
18.5.5.3 Several proprietary flexible joints are available for jointing cast iron pipes and these may be
used with the specific approval of the authority, however, they shall be used strictly in accordance
with the manufacturer’s instructions.
18.5.5.4 For joints in small diameter cast iron piping, copper-alloy screwed unions or ferrules shall
be used, and for large dia. The joints shall be made by flanged connecting pieces.
18.5.6 Hydrostatic
The procedure for testing for leakage under pressure shall be as described in Appendix D of
Chapter 18 which is to be read in addition to 18.4.8. The joints of pipes and specials have to be
repaired till the leakage in the portion under test is within the specified limit indicated in Appendix-D.
18.5.7 Measurements
18.5.7.1 The net length of pipes as laid or fixed, shall be measured in the running metres correct to
a cm. specials shall be excluded and enumerated and paid for separately. The portion of the pipe
within the collar at the joints shall not be included in the length of pipe work.

18.5.7.2 Excavation, refilling, shoring and timbering in trenches masonry or concrete pillars and thrust
blocks, wherever required, shall be measured and paid for separately, under relevant items of work.
18.5.7.3 Lead caulked joints shall be measured and paid for separately.
18.5.8 Rate
above except for the items measured/enumerated separately under Para 18.4.7.1, 18.4.7.2, 18.4.7.3
which shall be paid for separately.
18.6 LAYING AND JOINTING OF G.I. PIPES (EXTERNAL WORK)

18.6.0 The specifications described in 18.4 shall apply, as far as applicable.
18.6.1 Trenches
The galvanised iron pipes and fittings shall be laid in trenches. The widths and depths of the
trenches for different diameters of the pipes shall be as in Table 18.11.
TABLE 18.11
Dia of pipe Width of trench Depth of trench
(mm) (cm) (cm)
15 to 50 30 60
65 to 100 45 75
At joints the trench width shall be widened where necessary. The work of excavation and refilling
shall be done true to line and gradient in accordance with general specifications for earth work in
trenches.
When excavation is done in rock, it shall be cut deep enough to permit the pipes to be laid on a
cushion of sand minimum 7.5 cm deep.
18.6.2 Cutting and Threading

Where the pipes have to be out or rethreaded, the ends shall be carefully filed out so that no
obstruction to bore is offered. The end of the pipes shall then be carefully threaded conforming to
the requirements of IS 554 with pipe dies and tapes in such a manner as will not result in slackness
of joints when the two pieces are screwed together. The taps and dies shall be used only for
straightening screw threads which have become bent or damaged and shall not be used for turning
of the threads so as to make them slack, as the later procedure may not result in a water tight joint.
The screw threads of pipes and fitting shall be protected from damage until they are fitted.
18.6.3 Jointing
The pipes shall be cleaned and cleared of all foreign matter before being laid. In jointing the pipes,
the inside of the socket and the screwed end of the pipes shall be oiled and rubbed over. Teflon Tape
should be used on threads instead of ‘Dhaaga/ Safeda’. The end shall then be screwed in the socket,
Tee etc. with the pipe wrench. Care shall be taken that all pipes and fittings are properly jointed so as
to make the joints completely water tight and pipes are kept at all times free from dust and dirt during
fixing. Burr from the joint shall be removed after screwing. After laying, the open ends of the pipes shall
be temporarily plugged to prevent access of water, soil or any other foreign matter.
18.6.4 Thrust Blocks (Fig. 18.8)

In case of bigger diameter pipes where the pressure is very high, thrust blocks of cement concrete
1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate of 20 mm nominal size) of adequate size
and shape shall be provided on all bends to transmit the hydraulic thrust to the ground, spreading it
over a sufficient areas, depending upon the type of soil met with.

18.6.5 Painting
The pipes shall be painted with two coats of anticorrosive bitumastic paint of approved quality.
18.6.6 Testing of Joints

The pipes and fittings after they are laid and jointed shall be tested to hydraulic pressure of 6 Kg/
sq. cm (60 meter). The pipes shall be slowly and carefully charged with water allowing all air to
escape and avoiding all shock or water hammer. The draw off taps and stop cocks shall then be
closed and specified hydraulic pressure shall be applied gradually. Pressure gauge must be accurate
and preferably should have been recalibrated before the test. The test pump having been stopped,
the test pressure should be maintained without loss for at least half an hour. The pipes and fittings
shall be tested in sections as the work of laying proceeds, having the joints exposed for inspection
during the testing. Pipes or fittings which are found leaking shall be replaced and joints found leaking
shall be redone, without extra payment.
18.6.7 Trench Filling

The pipes shall be laid on a layer of 7.5 cm sand and filled up to 15 cm above the pipes. The
remaining portion of the trench shall then be filled with excavated earth as described in 20.3.7. The
surplus earth shall be disposed off as directed.
18.6.8 Measurements
The lengths shall be measured in running metre correct to a cm for the finished work, which shall
include G.I. pipe and G.I. fittings such as bends, tees, elbows reducers, crosses, plugs, sockets,
nipples and nuts, but exclude brass or gun metal taps (cocks), valves, unions, lead connection pipes
and shower rose. All pipes and fittings shall be classified according to their diameters, method of
jointing and fixing substance quality and finish. In case of fittings of an equal bore the pipe shall be
described as including all cuttings and wastage. In case of fittings of unequal bore the largest bore
shall be measured.
Note: G.I. unions shall be paid for separately in external work as well as in internal work.
Digging and refilling of trenches shall either be measured separately as specified in the appropriate
clauses of excavation and earth work or clubbed with main item.
18.6.9 Rate
above. The rate shall not include excavation in trenches, painting of pipes and sand filling all round
the pipes, unless otherwise specified.
18.7 LAYING AND JOINTING G.I. PIPES (INTERNAL WORK)

18.7.0 For internal work the galvanised iron pipes and fittings shall run on the surface of the walls or
ceiling (not in chase) unless otherwise specified. The fixing shall be done by means of standard
pattern holder bat clamps, keeping the pipes about 1.5 cm clear of the wall. When it is found necessary
to conceal the pipes, chasing may be adopted or pipes fixed in the ducts or recess etc., provided
there is sufficient space to work on the pipes with the usual tools. The pipes shall not ordinarily be
buried in walls or solid floors. Where unavoidable, pipes may be buried for short distances provided
adequate protection is given against damage and where so required joints are not buried. Where
directed by the Engineer-in-Charge, a M.S. tube sleeve shall be fixed at a place the pipe is passing
through a wall or floor for reception of the pipe and to allow freedom for expansion and contraction
and other movements. In case the pipe is embedded in walls or floors it should be painted with
anticorrosive bitumastic paints of approved quality. The pipe shall not come in contact with lime
mortar or lime concrete as the pipe is affected by time. Under the floors the pipes shall be laid in layer
of sand filling as done under concrete floors.

All pipes and fittings shall be fixed truly vertical and horizontal unless unavoidable. The pipes
shall be fixed to walls with standard pattern holder bat clamps of required shape and size so as to fit
tightly on the pipes when tightened with screwed bolts, these clamps shall be embedded in brick work
in cement mortar 1:3 (1 cement: 3 coarse sand), and shall be spaced at regular intervals in straight
lengths as shown in Table 18.12.
The clamps shall be fixed at shorter lengths near the fittings as directed by the Engineer-in-Charge.
For G.I. pipes 15 mm diameter, the holes in the walls and floors shall be made by drilling with
chisel or jumper and not by dismantling the brick work or concrete. However, for bigger dimension
pipes the holes shall be carefully made of the smallest size as directed by the Engineer-in-Charge.
After fixing the pipes the holes shall be made good with cement mortar 1:3 (1 cement: 3 coarse sand)
and properly finished to match the adjacent surface.
TABLE 18.12
Dia. of Pipe (mm) Horizontal length (m) Vertical length (m)
15 2 2.5
20 2.5 3
25 2.5 3
32 2.5 3
40 3 3.5
50 3 3.5
65 3.5 5
80 3.5 5
Unions will be provided to facilitate connections additions and alterations as well as for maintenance and
for change of pipes. The locations where unions are to be provided will be decided with prior written approval
of the Engineer-in-Charge.
18.7.1 Measurements
The lengths shall be measured in running metre correct to a cm for the finished work, which shall include
G.I. pipe and G.I. fittings such as bends, tees elbows, reducers, crosses, plugs, sockets, nipples and nuts,
but exclude brass or gun metal taps (cocks), valves, unions, lead connection pipes and shower rose. All pipes
and fittings shall be classified according to their diameters, method of jointing and fixing substance, quality
and finish. In case of fittings of an equal bore the pipe shall be described as including all cuttings and waste.
In case of fittings of unequal bore, the largest bore shall be measured. Pipes laid in trenches (or without
supports) and pipes fixed to walls, ceilings, etc. with supports shall be measured separately.
18.7.2 Rate
The rate shall include the cost of labour and material involved in all the operations described above. The
rate shall include the cost of cutting holes in walls and floors and making good the same. This shall not
however, include concealed pipe work in which case cutting of chase and making good shall be paid separately.
It shall not include painting of pipes and providing sleeves, unless specified otherwise. It will also not include
union which shall be paid for separately.
18.8 POLYPROPYLENE RANDOM CO-POLYMER (PP-R) PIPES

18.8.1 The PP-R is a bonded, multilayer pipe consisting of different layers of the pipe:-
(a) The inner-most layer of the pipe to be Anti – bacterial to prevent bacteria growth inside pipe surface.
(b) The middle layer to be of plain PP-R which is neither in contact with Water and nor under direct
effect of the atmospheric conditions.
(c) The outer-most layer to be of U.V. stabilized PP-R to prevent the pipe surface from sunlight under
exposed atmospheric conditions.

The pipes should in general be conforming to the requirements of IS 15801 except that specified with
in nomenclature of the item. The pipes should have smooth inner surface with non-contracting
diameters. The pipes shall be cleanly finished, free from cracks and other defects. The pipes shall
be clean and well cut along ends after taking into consideration the desired length, using the pipe
scissors. The Polypropylene used for manufacturing the pipe shall conform to the requirements of IS
10951 and IS 10910. The specified base density shall be between 900 kg/m3 and 910 kg/m3 when
determined at 27°C. The resin should be mixed with sufficient quantity of colour master batches. The
colour master batch should be uniform throughout the pipe surface. The standard dimension ratio
(SDR) i.e. ratio of the nominal outer diameter of a pipe to its nominal wall thickness should be 7.4/11
as given in the item.
18.8.2 Fittings
Plain fittings, Chrome plated brass threaded fittings and Valves shall be as per nomenclature
of item or as directed by engineer- in- charge.
(a) The plain fittings shall be Polypropylene Random Copolymer and comply with all the
requirements of the pipes. The plain fittings shall comprise of Socket, Elbow, Tee, Cross,
Reducer socket, Reduction Tee, End Cap, Crossover, Omega, Threaded Plug and wall
clamps in available sizes.
(b) The Chrome Plated Brass threaded fittings shall be Chrome Plated Brass threaded piece
molded inside Polypropylene random copolymer fitting. The maternal shall comply with all
the requirements of the pipes. The Chrome plated Brass threaded fittings shall comprise of
Socket, Elbow and Tee (Male & Female) in available sizes. These are the fittings for C.P.
connections and for continuations from existing Galvanized Irion Pipes and fittings.
(c) The valves shall be Polypropylene Random Copolymer Valves. The valves comprise of
Gate Valve, Ball Valve, Concealed stop valve and Chrome Coated Valve in available sizes.
The Valves sizes availability in Polypropylene Random Copolymer is as follows:-

(i) Gate Valve - 20 mm to 63 mm
(ii) Ball Valve - 20 mm, 25 mm, 32 mm, 40 mm, 50 mm & 63 mm
(iii) Concealed Stop valve - 20 mm & 25 mm
(iv) Chrome Coated Valve - 20 mm & 25 mm
However, the other Brass/Bronze Valves can be connected to Polypropylene Random pipes using
C.P. Brass threaded fittings of desired sizes.
18.8.3 Laying and Jointing of Pipes and Fittings

The specifications described in 18.4 shall apply as far as possible. The pipes and fittings shall
run in wall chase as specified. Pipes shall run only in vertical or horizontal alignment as far as
possible. The installation of pipes is similar to that of the metal pipes with the only difference in the
jointing procedure. The jointing of the PP-R pipes and fittings are done by fusion welding by means
of a welding machine. The marking on pipe shall carry the following information:-
(c) Manufacturer’s name/ trade mark
(d) PPR pipe
(e) SDR-
(f) Out side diameter and minimum wall thickness
(g) Lot No. / Batch No. containing date of manufacturing. And machine number.
18.8.4 The out side diameter of pipes, tolerance in the same and ovality of pipe shall be as given
in Table 18.13 below.

TABLE 18.13
Outside Diameter, Tolerance and Ovality of Pipes
Sl. No. Nominal Size Outside Diameter Tolerance (Only positive tolerance) Ovality
DN (mm) (mm) (mm)
(i) 16 16.0 0.3 1.2
(ii) 20 20.0 0.3 1.2
(iii) 25 25.0 0.3 1.2
(iv) 32 32.0 0.3 1.3
(v) 40 40.0 0.4 1.4
(vi) 50 50.0 0.5 1.4
(vii) 63 63.0 0.6 1.6
(viii) 75 75.0 0.7 1.6
(ix) 90 90.0 0.9 1.8
(x) 110 110.0 0.9 2.2
1. The values specified for tolerance on outside diameter have been calculated as 0.009DN,
rounded off to the next higher 0.1 mm subject to minimum of 0.3 mm. No negative tolerances are
allowed.
2. The basis for the values specified for ovality is:
(a) For nominal outside diameters < 75mm, the tolerance equals (0.008 DN+1.0) mm,
rounded to the next higher 0.1 mm, with a minimum value of 1.2 mm.
(b) For nominal outside diameters > 75mm and < 250mm, the tolerance equals
0.20 DN, rounded to the next higher 0.1 mm.
(c) For nominal outside diameter > 250 mm, the tolerance equals 0.35 DN, rounded to the
next higher 0.1 mm.
18.8.5 Wall Thickness

The minimum and maximum wall thickness of pipes shall be as given in Table 18.14 below:-
TABLE 18.14
Sl. No. Nominal Size SDR 11 SDR 7.4
DN Min Max Min Max
(1) (2) (3) (4) (5) (6)
(i) 16 - - 2.20 2.70
(ii) 20 1.90 2.30 2.80 3.30
(iii) 25 2.30 2.80 3.50 4.10
(iv) 32 2.90 3.40 4.40 5.10
(v) 40 3.70 4.30 5.50 6.30
(vi) 50 4.60 5.30 6.90 7.80
(vii) 63 5.80 6.60 8.60 9.70
(viii) 75 6.80 7.70 10.30 11.60
(ix) 90 8.20 9.30 12.30 13.80
(x) 110 10.00 11.20 15.10 16.90
Note: The wall thickness tolerances have been calculated on the following basis:
(a) Limit deviation=0.1e + 0.2 mm rounded up to the nearest 0.1 mm.
(b) A local increase in wall thickness of up to +0.2e is permissible for e up to 10 mm and up to
0.15e for e greater than 10 mm. The mean of the measurement shall, however, still lie
within the given limit deviations.

The quality of each installation system ultimately depends on the tightness, stability and lifetime
of its connections. The pipe of the desired length is cut using the pipe scissors. The proper heating
piece is taken and mounted on the welding machine. The welding device is switched on - Control
lamp and switch lamp will lit. When ready, control lamp gets off, which means that welding temperature
of 260 Degrees ±10 Degrees Celsius has been reached. The pipe end and the fitting to be welded
are heated on the welding machine. Before heating the fitting and the pipe, the dirty welding tools,
pipe and fitting are cleaned with a cloth. When heated up (with heating time as per the Table shown
below), the pipe and the fitting is removed from the welding machine and the two pieces connected
together by applying a little pressure without twisting. The joint is allowed to cool down for a few
seconds. The welding process is that safe because the properly heated part of Polypropylene create
a homogeneous connection.
Guidelines for Welding PP-R Pipes and Fittings (DVS Guideline 2207, Part II)
Outer diameter of pipe(mm) Heating Time (Seconds) Cooling Period (Minutes)
16 5 2
20 5 2
25 7 2
32 8 4
40 12 4
50 18 4
63 24 6
75 30 8
90 30 8
The same procedure shall be adapted for exposed as well as concealed fittings. The Crossovers
may be used wherever the overlapping of the PP-R pipes is required. The fixing shall be done by
means of Wall Support Clamps keeping the pies about 1.5 cm clear of the wall where to be laid on the
surface. Where it is specified to conceal the pipes, chasing may be adopted. For pipes fixed in the
shafts, ducts etc. there should be sufficient space to work on the pipes with the usual tools. Pipe
sleeves shall be fixed at a place the pipe is passing, through a wall or floor for reception of the pipe
and allow freedom for expansion and contraction and other movements. Fixed supports prevent any
movement of the pipe by fixing it at some points. Fittings are used in creating the fixed points. Fixed
supports must not but installed at bending parts and the direction changes must be done in the pipe
itself. In between the fixed supports some arrangements must be done to compensate any potential
elongation or shrinkage in the pipe length. For exposed straight pipes having length more than 5
meters, to compensate the expansion an expansion piece must be used.
18.8.6 Piping Installation Support

Piping shall be properly supported by means of wall support clamps as specified and as required,
keeping in view the proper designing for expansion and contraction. Risers shall be supported at
each floor with clamps.Due to high coefficient of thermal expansion the heat losses though the pipes
is highly reduced. Therefore, for internal Bathroom hot geyser water distribution lines, the insulation
is often not required.
18.8.7 Installation of Water Meter and Valves

PP-R lines shall be cut to the required lengths at the position where the meter and Valves are
required to be fixed. Suitable C.P. Brass threaded fittings shall be attached to the pipes. The meter
and Valves shall be fixed in a position by means of connecting pipes, jam nut and socket etc. The
stop cock shall be fixed near the inlet of the water meter. The paper disc inserted in the ripples of the
meter shall be removed. And the meter shall be installed exactly horizontally or vertically in the flow
line in the direction shown by the arrow cast on the body of the meter. Care shall be taken to not to
disturb the factory seal of the meter. Wherever the meter shall be fixed to a newly fitted pipeline, the
pipeline shall have to be completely washed before fitting the meter.

18.8.8 Testing
All water supply system shall be tested to Hydrostatic pressure test. Maximum operating pressure
at varying degree of temperature is given in Table 18.15:-
TABLE 18.15
Sl. No. Temperature SDR 11 SDR 7.4
Pressure MPa Pressure MPa
(i) 10 1.91 3.02
(ii) 20 1.63 2.58
(iii) 30 1.37 2.17
(iv) 40 1.15 1.84
(v) 50 0.98 1.55
(vi) 60 0.82 1.28
(vii) 70 0.62 0.98
(viii) 80 0.39 0.62
(ix) 95 0.27 0.4
The pressure test is performed in 3 steps being preliminary test, main test and final test. For the preliminary
test a pressure which is 1.5 times higher than the possible working pressure is applied and this is repeated
two times in 30 minutes with intervals of 10 minutes. After a test period of 30 minutes, the test pressure must
not be dropped more than 0.6 bar and no leak must occur. Main test follows the preliminary test. Test time is
two hours, in doing so the test pressure taken from the preliminary test must not have fallen more than 0.2 bar.
After completion of these tests, the final test comes which has to be done under a test pressure of 10 bars
and 5 bar in the interval of 15 minutes. Between the respective test courses, pressure has to be removed.
All leaks and defects in joints revealed during the testing shall be rectified and got approved at site by
retest. Piping required subsequent to the above pressure test shall be retested in the same manner.
System may be tested in sections and such sections shall be entirely checked on completion of connection
to the overhead tanks or pumping system or mains. In case of improper circulation, the contractor shall rectify
the defective connections. He shall bear all expenses for carrying out the above rectifications including the
tearing up and refinishing of floors and walls as required.
After commissioning of the water supply system, contractor shall test each valve by closing and opening
it a number of times to observe if it is working efficiently. Valves which are not working efficiently shall be
replaced by new ones.
18.8.9 Measurements
The net length of pipes as laid or fixed shall be measured in running meters correct to a cm for the finished
work, which shall include PP -R pipe and fittings including plain fittings and Chrome Plated Brass Threaded
fittings. Deductions for the length of valves shall be made. The cost includes cutting chases in the masonry
wall and making good the same, trenching, refilling and testing of joints. The cost of gate valves/ wheel valves/
union shall be paid for separately.
18.9 CHLORINATED POLYVINYL CHLORIDE (CPVC) PIPES

18.9.1 CPVC pipes & fittings used in hot & cold potable water distribution system shall conform to requirement
of IS 15778. The material from which the pipe is produced shall consist of chlorinated polyvinyl chlorides.
The polymer from which the pipe compounds are to be manufactured shall have chlorine content not less
than 66.5%.
The internal and external surfaces of the pipe shall be smooth, clean and free from grooving and other
defects. The pipes shall not have any detrimental effect on the composition of the water flowing though it.
Diameter and wall thickness of CPVC pipes are as per given in Table 18.16 below.

TABLE 18.16
Sl.No Nominal Nominal Mean Outer Wall Thickness
size outer Outside diameter at Class 1, SDR 11 Class 3, SDR 17
diameter Diameter any point
Max Min Max Min Avg. Min Max Avg. Min Max
Max Max
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
(i) 15 15.9 15.8 16.0 15.8 16.0 2.2 1.7 2.2 - - -
(ii) 20 22.2 22.1 22.3 22.0 22.4 2.5 2.0 2.5 - - -
(iii) 25 28.6 28.5 28.7 28.4 28.8 3.1 2.6 3.1 - - -
(iv) 32 34.9 34.8 35.0 34.7 35.1 3.7 3.2 3.7 - - -
(v) 40 41.3 41.2 41.4 41.1 41.5 4.3 3.8 4.3 - - -
(vi) 50 54.0 53.9 54.1 53.7 54.3 5.5 4.9 5.5 - - -
(vii) 65 73.0 72.8 73.2 72.2 73.8 - - - 4.8 4.3 4.8
(viii) 80 88.9 88.7 89.1 88.1 89.7 - - - 5.9 5.2 5.9
(ix) 100 114.3 114.1 114.5 113.5 115.1 - - - 7.5 6.7 7.5
(x) 150 168.3 168.0 168.6 166.5 170.1 - - - 11.1 9.9 11.1
Notes
1. For CPVC pipes SDR is calculated by dividing the average outer diameter of the pipe in mm by the
minimum wall thickness in mm. If the wall thickness calculated by this formula is less than 1.52
mm, it shall be increased to 1.52 mm. The SDR values shall be rounded to the nearest 0.5.
18.9.2 Dimensions of Pipes

The outside diameter, outside diameter at any point and wall thickness shall be as given in Table 18.16.
18.9.2.1 Diameter : The outside diameter and outside diameter at any point as given in Table 18.16 shall be
measured according to the method given in IS 12235 (part 1).
18.9.2.2 Diameter at any point : The difference between the measured maximum outside diameter and measured
minimum outside diameter in the same cross-section of pipe (also called tolerance on ovality) shall not
exceed the greater of the following two values:
(a) 0.5 mm, and
(b) 0.012 dn rounded off to the next higher 0.1 mm.
18.9.2.3 Wall Thickness : The wall thickness of the pipes shall be as given in Table 18.16. Wall thickness
shall be measured by any of the three methods given in IS 12235 (part 1). To check the conformity of the wall
thickness of the pipe throughout its entire length, it is necessary to measure the wall thickness of the pipe at
any point along its length. This shall be done by cutting the pipe at any point along its length and measuring
the wall thickness as above. Alternatively, to avoid destruction of the pipe, non destructive testing methods
such as the use of ultrasonic wall thickness measurement gauges shall be used at any four points along the
length of the pipe.
Tolerance on Wall Thickness

(a) For pipes of minimum wall thickness 6 mm or less, the permissible variation between the minimum
wall thickness (eMin) and the wall thickness at any point (e), (e - eMin) shall be positive in the form of
+y, where y=0.1 eMin+0.2 mm.
(b) For pipes of minimum wall thickness greater than 6mm, the permissible variation of wall thickness
shall again be positive in the form of +y, where y would be applied in two parts.
(c) The average wall thickness shall be determined by taking at least six measurements of wall thickness
round the pipe and including both the absolute minimum and absolute maximum measured values.
The tolerance applied to this average wall thickness from these measurements shall be within the
range 0.1 eMin+0.2 mm (see Table 18.16).
(d) The maximum wall thickness at any point shall be within the range 0.15eMin (see Table 18.16).
(e) The results of these calculations for checking tolerance shall be rounded off to the next higher 0.1 mm.

18.9.2.4 Effective Length (Le) : If the length of a pipe is specified, the effective length shall not be less than
that specified. The preferred effective length of pipes shall be 3, 5 or 6 m. The pipes may be supplied in other
lengths where so agreed upon between the manufacturer and the purchaser.
18.9.3 Pipe Ends

The ends of the pipes meant for solvent cementing shall be cleanly cut and shall be reasonably square to
the axis of the pipe or may be chamfered at the plain end.
18.9.4 Physical and Chemical Characteristics

18.9.4.1 Visual Appearance : The colour of the pipes shall be off-white. Slight variations in the appearance of
the colour are permitted.
The internal and external surface of the pipe shall be smooth, clean and free from grooving and other
defects.
18.9.4.2 Opacity : The wall of the plain pipe shall not transmit more than 0.1 per cent of the visible light falling
on it when tested in accordance with IS 12235 (Part 3).
18.9.4.3 Effect on Water : The pipes shall not have any determinate effect on the composition of the water
flowing through them, when tested as per 10.3 of IS 4985.
18.9.4.4 Reversion Test : When tested by the method prescribed in IS 12235 (Part 5/ Sec 1 and Sec 2), a
length of pipe 200 ±20 mm long shall not alter in length by more than 5 per cent.
18. 9.4.5 Vicat Softening Temperature : When tested by the method prescribed in IS 12235 (part 2), the
Vicat softening temperature of the specimen shall not be less than 110°C.
18.9.4.6 Density : When tested in accordance with IS 12235 (Part 14), the density of the pipes shall be
between 1450kg/m3 and 1650kg/m3.
18.9.5 Mechanical Properties

18.9.5.1 Hydrostatic Characteristics : When subject to internal hydrostatic pressure test in accordance with
the procedure given in IS 12235 (part 8/Sec 1), the pipe shall not fail during the prescribed test duration. The
temperatures, duration and hydrostatic (hoop) stress for the test shall conform to the requirements given in
Table 18.17. The test shall be carried out not earlier than 24 h after the pipes have been manufactured.
TABLE 18.17
Requirements of Pipes for Internal Hydrostatic Pressure Test
(Clause 18.9.5.1)
Sl. No. Test Test Temperature Min Test Period Hydrostatic (Hoop) Stress
°C h MPa
(1) (2) (3) (4) (5)
(i) Acceptance 20 1 43.0
(ii) Type 95 165 5.6
(iii) Type 95 1000 4.6
(iv) Type 95 8760 3.6 (Test for thermal
stability)
18.9.5.2 Thermal Stability by Hydrostatic Pressure Testing : When subject to internal hydrostatic pressure
test in accordance with the procedure given in IS 12235 (Part 8/Sec 1) and as per requirement given in Table
18.17, Sl. No. (iv), the pipe shall not burst or leak during the prescribed test duration.
18.9.5.3 Resistance to External Blow at 0°C : When tested by the method prescribed in IS 4985, with
classified striker mass and drop height as given in Table 18.18, the pipe shall have a true impact rate of not
more than 10 per cent.

TABLE 18.18
Classified Striker Mass and Drop Height Conditions for the Falling Weight Impact Test
(Clause 18.9.5.3)
Sl. No. Nominal Pipe Size Mass of Falling Weight Falling Height
mm Kg mm
(1) (2) (3) (4)
(i) 15 0.5±0.5% 300±10
(ii) 20 0.5±0.5% 400±10
(iii) 25 0.5±0.5% 500±10
(iv) 32 0.5±0.5% 600±10
(v) 40 0.5±0.5% 800±10
(vi) 50 0.5±0.5% 1000± 10
(vii) 65 0.8±0.5% 1000±10
(viii) 80 0.8±0.5% 1200±10
(ix) 100 1.0±0.5% 1600±10
(x) 150 1.6±0.5% 2000±10
18.9.5.4 Flattening Test : When tested by the method prescribed in IS 12235 (part 19), pipe shall show no
signs of cracking, splitting and breaking.
18.9.5.5 Tensile Strength : When tested by the method prescribed in IS 12235 (Part 19), the tensile strength
at yield shall not be less than 50 MPa at 27 ± 2°C.
18.9.6 Sampling and Criteria for Conformity

The sampling procedure and criteria for conformity shall be as given in Annexure F.
18.9.7. Marking
18.9.7.1 Each pipe shall be clearly and indelibly marked in ink/paint or hot embossed on white base at
intervals of not more than 3 m. The marking shall show the following:
(a) Manufacturer’s name or trade-mark
(b) Outside diameter,
(c) Class of pipe and pressure rating, and
(d) Batch or lot number
18.9.7.2 BIS Certification Marking : Each pipe may also be marked with the Standard Mark.
18.9.8 Fittings
The fittings shall be as follows:
(a) Plain CPVC solvent cement fittings from size 15 mm to 160 mm.
(b) Brass threaded fittings.
(c) Valve from size 15 mm to 160 mm
(d) Brass Threaded Fittings: All types of one end brass threaded male/female adaptors in various fittings
like coupler, socket, elbow, tee are available for transition to other plastic/metal piping and for fixing
of CP fittings. Ball, Gate valves in CPVC are available in all dimensions. All fittings shall carry the
following information:
(1) Manufacturer’s name/trade mark.
(2) Size of fitting
18.9.9 Piping Installation Support and Spacing

18.9.9.1 Concealed Piping: Pipes can be concealed in chases. The pipes and fitting are to be pressure
tested prior to concealing the chases. To maintain alignment of CP fittings while joining, all alignment of
fittings and pipe shall be done correctly. DO NOT USE NAILS FOR HOLDING OF PIPES IN THE CHASES.

18.9.9.2 External Installations: For pipes fixed in the shafts, ducts etc. there should be sufficient
space to work on the pipes. Pipes sleeves shall be fixed at a place the pipe is passing through a wall
or floor so as to allow freedom for expansion and contraction. Clamping of the pipe is done to
support it while allowing the freedom for movement.
All pipes exposed to sunlight shall be painted with a water based acrylic paint emulsion to enhance
UV protection. Pipes in trenching shall be laid in accordance to the Good Plumbing practices followed
for Metal piping.
Recommended Support Spacing (Distance between Pipe Clamps Horizontal Support)

Pipe Size Horizontal Support (In meters)
Temperature
23°C 38°C 60°C 82°C
16 mm (1/2”) 1.22 1.22 1.07 0.92
20 mm (3/4”) 1.53 1.37 1.22 0.92
25 mm (1/0”) 1.68 1.3 1.37 0.92
32 mm (1 1/4”) 1.83 1.68 1.53 1.22
40 mm (1 1/2”) 1.98 1.83 1.68 1.22
50 mm (2”) 2.29 2.14 1.98 1.22
18.9.9.3 Expansion LOOP: CPVC systems, like all piping materials, expand and contract with changes
in temperatures. CPVC pipes shall expand 7.5 cm per 30 m length for a 400C temperature change.
Expansion does not vary with Pipe size. Thermal expansion can be generally be accommodated at
changes in direction. On a long straight run, an offset or loop based on the following chart is required.
Nominal Pipe Length of Run (Meter), Loop length in cms.
Size 6 metre 12 metre 18 metre 24 metre 30 metre
15 mm 43 56 69 79 86
20 mm 48 66 81 91 104
25 mm 53 74 91 104 117
32 mm 58 81 102 117 130
40 mm 63 89 109 127 142
50 mm 71 102 124 145 63
18.9.10 Testing
All water supply systems shall be tested to hydrostatic pressure test. The pressure tests are
similar to the test pressure used for other plastic/metal pipes. System may be tested in sections and
such section shall be entirely checked on completion of connection to the overhead tank or pumping
system or mains.
The net length of pipes as laid or fixed shall be measured in running meters correct to a cm for
the finished work, which shall include CPVC pipe and fittings including plain and Brass threaded
fittings and jointing solvent cement.
18.10 PE-AL-PE PIPES

18.10.1 The PE-AL-PE pipes are bonded, multilayer pipes consisting of metal aluminium and
polyethylene i.e. metallic pipe bonded with adhesive both internally and externally by polyethylene
coating. The layers of PE-AL-PE pipes are:-
(i) The interior layer of polyethylene
(ii) The adhesive layer
(iii) Aluminium tube

(iv) The adhesive layer
(v) The external layer of polyethylene
Polyethylene composite pressure pipes have welded aluminium tube reinforcement between inner
and outer polyethylene layers, inner and outer polyethylene layer being bonded to aluminium tube
by melt adhesive and are manufactured as per IS 15450
The specially manufactured compression joints fittings should be used for PE -AL-PE pipes which
are available in 3 types i.e. brass, composite and composite external sealing. Either of these fittings
should be used. The external sealing fittings should be used only for cold water applications.
18.10.2 (i) Polyethylene compounds shall conform to IS 7328 as follows:

(a) PEEWA 45 T006 for black pipes and
(b) PEELA 45 T006 for coloured pipes.
(ii) Aluminium shall have following properties:

(a) Minimum elongation: 20%
(b) Ultimate tensile strength: 100 MPa.
The aluminium strip shall have nominal thickness as specified in Table 18.19 (i).
Tolerances on all thickness for all sizes shall be (+) 0.02 mm.
TABLE 18.19 (i)

Aluminium Thickness and Tolerances for PE-AL-PE Pipe
S. No. Nominal Pipe Size (mm) Nominal Aluminium Thickness (mm)
(i) 1216 0.20
(ii) 1620 0.25
(iii) 2025 0.25
(iv) 2532 0.30
(v) 3240 0.30
(vi) 4050 0.30
(iii) Dimensions of pipes shall be as given in Table 18.19 (ii).
TABLE 18.19 (ii)

S. Nominal pipe Nominal Total wall thickness Outer PE layer
No. size outside Minimum Maximum Thickness
(mm) diameter (mm) (mm) Minimum
(OD) (mm)
(mm)
(i) 1216 16 1.75 2.00 0.40
(ii) 1620 20 2.00 2.25 0.40
(iii) 2025 25 2.45 2.70 0.40
(iv) 2532 32 2.80 3.20 0.40
(v) 3240 40 3.40 3.80 0.40
(vi) 4050 50 4.00 4.40 0.40
(iii) Dimensions of pipes shall be as given in Table 18.19 (ii).
(iv) The PE-AL-PE composite pipe shall be pressure rated for maximum water pressures
of 1.38 MPa at 23°C and 1.10 MPa at 60°C.

18.10.3 Jointing
While jointing PE-AL-PE pipes, following steps are required to be taken to ensure a leak proof
and strong pipe joint:-
(a) Cut the pipe square by cutter to the required and proper length.
(b) Select the fitting to be used and dismantle its nuts and split rings.
(c) Place the nut and split ring over the pipe. Ensure that ‘O’ rings are in proper position of
insert.
(d) Prepare the end of pipe to be jointed for roundness and chamfer by using beveling tool.
Push the pipe over the insert and inside the support groove fully.
(e) Push the split ring and nut towards connector till split ring touches the support groove.
(f) Tighten the nut over connector with spanner.
If the joints are required to be dismantled for any reason, the ‘O’ ring and split ring should be
inspected before reassembling the joint for any damage. If any ring is found damaged, the same
should be replaced. All other components can be reused. The joint sealing with fittings is done by
silicone rubber ring. No thread sealing is involved. Tightening of the nuts is required only for
compressing the spilt ring over the pipe, hence excessive tightening of the nuts is to be avoided. In
case threading is required for fixing valves and fixtures, then select the fittings already having male
or female thread as per the requirement.
18.10.4 Fixing in Portion of PE-AL-PE Pipes

For installation of PE-AL-PE pipes and fittings, following steps are required to be taken to ensure
easy and faster installation:-
18.10.4.1 Measure the exact length of pipe required from fitting to fitting.
18. 10.4.2 Cut pipe to required length by using PE-AL-PE pipe cutter to ensure clean and square
cut. If the cut is not proper then the joint will not be proper/leak proof.
18.10.4.3 Use external bending spring for straightening of the PE-Al-PE pipes which are available in
coils. If there are any bends in between then insert the external bending spring over the pipe and
bend it to required angle. Move the spring after bending to next bending location. After putting the
pipe in position completely, remove the spring. If the ends of pipes are required to be bent then the
external bending spring may not support the pipe fully. In such cases, use internal bending spring.
Use of bending springs facilitates bending of pipe to desired radius without causing any deformation
to the pipe.
18.10.4.4 While connecting the fitting to the end of the pipe, follow the jointing procedure.
The PE-AL-PE pipe can be bent easily to the required shape. The bending shall be done in such
a way that the bending radius is not less than 5 times the outer diameter of the pipe. As the pipe
stays in shape, elbows are generally not required. Due to the unique jointing system, unions are not
at all required. Bending of PE-AL-PE pipe in ‘L’ shape is not recommended. Use elbow in case it is
absolutely necessary.
18.10.4.5 PE-AL-PE pipe can be installed in both internal and external work. For concealed work the
walls can be recessed by hand or mechanical router for speed. Where PE-AL-PE pipe are installed
on the surface, the maximum clipping center should be kept as Table 18.20.

Table 18.20
Pipe size Horizontal Vertical
(mm) (mm)
1216 800 1000
1620 800 1000
2025 1000 1200
2532/3250 1200 1500
The pipes installed on surface must have two additional clamps at fittings other than as specified
above.
18.10.4.6 It is necessary to provide clip/hook at the threaded fittings.
18.10.4.7 Only Teflon Tape should be used on threads instead of ‘Dhaaga/ Safeda’. While for fittings,
specially designed rubber “Seal” should be used.
18.10.5 For pressure testing the pipeline system, specially designed test plugs are to be used in
female thread elbows instead of ordinary GI nipples with MS plugs before covering the pipes in
chases.
18.10.6 Diameter of pipes should be increased from 16 mm OD to 20 mm OD when the user points
exceed three. The head recommended for flush valve in gravity flow system is minimum 10 meters for
3240 mm size pipe. For optimum calculations and further design IS 15450 and “manufacturer’s
plumbing design guidelines” should be referred.
18.10.7 Storing Precautions

18.10.7.1 PE -AL- PE pipe should be stacked carefully so as to prevent them from falling or causing
damage with any external sharp edged material. PE-AL-PE pipe is a tough material but needs greater
protection from accidental damages when installed in comparison to metallic pipes.
18.10.7.2 Where PE-AL- PE pipe is to be connected to heavy items such as pumps or valves it is
likely to impose undue strain in the pipes, hence the pump or valve should be supported directly
using the support bracket.
18.10.7.3 The PE-AL-PE pipe are malleable, hence these should be protected from any heavy load/
impact and drilling etc. Where these pipes are provided under the ground, adequate cover as per IS
15450 should be provided.
18.10.8 The maximum allowable parameters for various components of PE-AL-PE piping system are
given in Table 18.21.
TABLE 18.21
Fluid Service Maximum allowable service pressure in bar
temperature PE-AL-PE Fitting Fitting Fitting end
deg ‘C’ pipe Internal Internal Seal
Sealing Sealing
Brass Composite Composite
Water Ambient 15 13 10 10
65 10 10 10 -
80 10 10 4 -

Before the pipes are covered or put to use, these should be tested for any leakage as per the
following table:-
The requirement of hydraulic test pressure are given in the following table at 20°C & 60°C
temperature respectively using water.
TABLE 18.22
Description Pressure in MPa
Nominal Pipe Size 1 Hour Test (20°C) 10 Hour Test (60°C)
1216 3.0 2.50
1620 2.70 2.50
2025 2.60 2.50
2532 2.30 2.10
3240 2.20 2.00
18.11 MAKING CONNECTION OF G.I. DISTRIBUTION BRANCH WITH G.I. MAIN

18.11.1 Preliminary Work
A pit of suitable dimensions shall be dug at the point where the connection is to be made with the
main and earth removed up to 15 cm below the main. The flow of water in the water main shall also
be disconnected by closing the sluice or wheel valves on the mains.
18.11.2 Making Connection

For cutting and jointing 18.6.2 and 18.6.3 shall apply. The G.I. main shall first be cut. Water if any
collected in the pit shall be bailed out and, ends of the G.I. pipes threaded. The connection of
distribution pipe shall then be made after fixing G.I. tee of the required size to the G.I. main and fittings
such as Jam nut, G.I. socket connecting piece etc.

After laying and jointing, the pipes and fittings shall be inspected under working condition of
pressure and flow. Any joint found leaking shall be redone and all leaking pipes removed and replaced
without extra payment.
The pipes & fittings after they are laid shall be tested to hydraulic pressure of 6 kg./sq.cm. (60 m).
The pipes shall be slowly and carefully charged with water allowing all air to escape and avoiding all
shock of water hammer. The draw of laps and stop cocks shall then be closed and specified hydraulic
pressure shall be applied gradually. Pressure gauge must be accurate and preferably should have
been recalibrated before the test. The test pump having been stopped, the test pressure should be
maintained without loss for at least half an hour. The pipes and fittings shall be tested in sections as the
work of laying proceeds, having the joints exposed for inspection during the testing.
18.11.4 Finishing
The portion of the pipe in the pit shall be painted with bitumastic paint and encased with sand 15
cm all-round. The pit shall be filled with earth in level with the original ground surface watered,
rammed and the area dressed.
The work of making connections shall be enumerated.
18.11.6 Rate
above.

18.12 FIXING BRASS AND GUN METAL WATER FITTINGS
18.12.0 The fitting shall be fully examined and cleared of all foreign matter before being fixed. The
fitting shall be fitted in the pipe line in a workman like manner. The joints between fittings and pipes
shall be leak-proof when tested to a pressure of 17.5 kg/sq.cm. The defective fittings and joints shall
be replaced or redone.
Fittings shall be enumerated.
18.12.2 Rate
The rate shall include cost of all the material and labour involved in all the operation described
above.
18.13 FIXING FERRULES

18.13.1 For fixing ferrule the empty main shall be drilled and tapped at 45 degree to the vertical and
the ferrule screwed in. The ferrule must be so fitted that no portion of the shank shall be left projecting
within the main into which it is fitted.
Ferrule shall be enumerated.
18.13.3 Rate
The rate shall include the cost of all materials and labour involved in fixing the ferrule.
18.14 INSTALLATION OF FIRE HYDRANT

18.14.1 The hydrant shall be fully examined and cleared of all foreign matter before being fixed. The
fixing shall be done on the water main which shall be of minimum 80 mm dia. The flanged end of the
hydrant shall be fixed to the flanged outlet of a tee in the water main by means of bolts, nuts and 3
mm rubber insertion or chemically treated compressed fiber board 1.5 mm minimum thickness and of
weight not less than 0.183 gm. per sq.cm. This can also be fixed by means of flanged tail piece which
may be connected to the water main by C.I. specials.
Fire hydrant shall be enumerated.
18.14.3 Rate
above against relevant item of work.
18.15 INSTALLATION OF SLUICE VALVE

18.15.1 The valve shall be fully examined and cleared of all foreign matter before being fixed. The
fixing of the valve shall be done by means of bolts, nuts and 3 mm rubber insertions or chemically
treated compressed fiber board 1.5 mm minimum thickness and of weight not less than 0.183 gm./
sq.cm. with the flanges of spigot and the socketed tail pieces drilled to the same specification in case
of S&S pipes and with flanges in case of flanged pipes. The tail pieces shall conform to IS 1938.
These shall be jointed to the pipe line by means of lead caulked joints.
Sluice valve shall be enumerated.
18.15.3 Rate
The rate shall include the cost of material and labour involved in all the operations described above.

18.16 INSTALLATION OF WATER METER AND STOP VALVE (FIG. 18.3 and 18.4)
18.16.0 The G.I. line shall be cut to the required length at the position where the meter and stop cock are
required to be fixed. The ends at the pipe shall then be threaded. The meter and stop cock shall be fixed in
position by means of connecting pipes, G.I. jam nut and socket etc. The stop cock shall be fixed near the inlet
of the water meter. The paper disc inserted in the nipples of the meter shall be removed and the meter installed
exactly horizontal or vertical in the flow line in the direction shown by the arrow cast on the body of the meter.
Care shall be taken that the factory seal of the meter is not disturbed. Wherever the meter shall be fixed to a
newly fitted pipe line, the pipe line shall have to be completely washed before fitting the meter. For this
purpose a piece of pipe equal to the length of the meter shall be fitted in the proposed position of the meter in
the new pipe line. The water shall be allowed to flow completely to wash the pipe line and then the meter
installed as described above by replacing the connecting piece.

Testing of joints shall be done as described in 18.6.6.
The work of fixing meters and stop cocks shall be counted in numbers separately according to the
diameters.
18.16.3 Rate
The rate shall include the cost of labour and materials involved in all the operations described above
excluding the cost of stop cock and water meter.
18.17 FIXING SURFACE BOX (FIG. 18.6)

18.17.1 The C.I. surface box shall be fixed on the top of masonry chamber in plain or reinforced cement
concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate 20 mm nominal size) as the case
may be.
Masonry chambers shall be enumerated under the relevant items.
18.17.3 Rate
The rate shall include the cost of materials and labour involved in all the operations described above,
except the excavation in saturated soil, soft or decomposed and hard rock if met with. The difference of cost,
between ordinary soil and saturated soil or soft or decomposed or hard rock as the case may be, shall be paid
for separately.
18.18 POLYETHYLENE WATER STORAGE TANKS

18.18.1 Material
Polyethylene used for manufacture of tanks and manhole lids may be high density (HDPE), low density
(LDPE) or linear low density (LLDPE) and shall conform to IS 10146. Polyethylene shall be compounded with
carbon black so as to make the tank resistant to ultra violet rays from the sun. The percentage of carbon
black content in polyethylene shall be 2.5 ± 0.5 percent and it shall be uniformly distributed. The materials
used for the manufacture of tank, manhole lid and fittings shall be such that they neither contaminate the
water nor impart any taste, colour, odour or toxity to water.
18.18.2 Manufacture and Finish

The tanks shall be manufactured by rotational moulding process. Each tank and the manhole lid shall be
single piece having arrangement for fixing and locking the manhole lid with the tanks. Excess material at the
mould parting line and near the top rim shall be neatly cut and finished. The internal and external surface of
the tanks shall be smooth, clean and free from hidden internal defects like air bubbles, pit and metallic or
other foreign material inclusion. Capacity of the tank, minimum weight of the empty tank (without manhole lid)
and the manufacture brand name shall be embossed on the top surface of the tank near manhole.

18.18.3 Shape, Size and Capacity
The tank shall be cylindrical vertical with closed top having a manhole. Diameter and height of the tank of
various capacities shall be as per manufacturer’s specifications and a clearance of ± 3 percent shall be permitted
on these dimensions. Capacity of the tank or up to the bottom of the inlet location whichever is less. Capacity
of the tank shall be specified. Extra capacity if any shall be ignored.
18.18.4 Weight and Wall Thickness

Minimum weight of the empty tank (exclusive of manhole lid fittings) and the minimum wall thickness of
top, bottom and sides shall be specified in Table 18.23. Wall thickness shall be checked beyond 150 mm of
the edge where the direction the plane of tank surface changes.
18.18.5 Installation and Fittings

The flat base of the tank shall be fully supported over its whole bottom area on a durable rigid flat and level
platform sufficiently strong to stand without deflection the weight of the tank when fully filled with water.
Depending upon the capacity and location tanks may be suitably anchored as per the directions of the
Engineer-in-Charge. For inlet, outlet and other connections fully threaded GI, HDPE or PVC connections with
hexagonal check nuts and washers on either side of the tank wall shall be provided. Holes for threaded
connections shall be drilled and not punched. Pipes entering of leaving the tank shall be provided with unions
and suitably supported on a firm base to avoid damage to the tank walls.
18.18.6 Manhole Lid

The lid shall rest evenly and fit over the rim of the manhole so as to prevent the ingress of any foreign
matter into the tank. The lid shall be provided with suitable arrangement for locking it with the tank.
18.18.7 The tank and its components shall conform to the local bye-laws for preventions of mosquito menace.
Dimensions shall be measured to the nearest cm. and weight of the empty tank shall be recorded to the
nearest 100g. Capacity of the tank as defined in 18.18.3 shall be calculated to the nearest litre.
TABLE 18.23
S.No Capacity Minimum Wall Thickness Minimum Weight of Empty Tank
litres mm kg
1 2 3 4
1. 200 4.4 7.8
2. 300 4.4 9.0
3. 400 5.5 15.0
4. 500 6.0 18.0
5. 700 6.6 23.5
6. 1000 7.0 33.0
7. 1250 7.0 40.0
8. 1500 7.0 47.0
9. 1700 7.0 54.0
10. 2000 8.2 64.0
11. 2500 8.2 81.0
12. 3000 8.8 96.0
13. 4000 10.4 138.0
14. 5000 10.7 191.0
15. 6000 10.7 209.0
16. 7500 10.7 250.0
17. 10000 11.5 363.0
18. 15000 11.5 550.0
19. 20000 13.2 814.0

18.18.9 Rates
The rate shall include the cost of the tank, manhole lid, carriage and delivery at the place specified.
Hoisting, installation, fittings, platform and anchoring shall be payable separately.
18.19 TUBE WELLS WITH HAND PUMPS

18.19.1 Casing Pipe
The casing pipe shall be of M.S. or W.I. of 100 mm dia. and strong enough to stand hammering
and vibrations to which it is subjects.
18.19.2 Filter and Brass Strainer

The filter shall consist of a G.I. pipe of the required diameter with 15 mm diameter holes covered
with brass strainer both inside and outside. It shall have a driving point riveted or welded to it.
18.19.3 Hand Pump

This shall be of approved quality. It shall be complete with necessary bolt and nuts for joining to
the masonry or concrete base.
18. 20 CUTTING HOLES IN WALL UPTO 30 × 30 CM

18.20.0 Square holes of size as specified or as directed by the Engineer-in-Charge shall be cut in
the masonry. Any damage to the adjoining portion or to any other item shall be made good as
directed by the Engineer-in-Charge. All dismantled material shall be removed from the site.
18.20.1 Masonry Work

Brick work etc. shall be made good by using the same class of brick, tile or stone masonry as was
cut during the execution of work. The mortar to be used shall be cement mortar 1:4 (1 cement: 4 fine
sand) or as directed by the Engineer-in-Charge.
18.20.2 Finishing
Cement mortar in 1:4 mix (1 cement: 4 sand) shall be used for plastering or pointing, as may be
required. Sand shall be fine or coarse, as used in the original work. The surface shall be finished with
two or more coats of white wash, colour wash, distemper or painting as required but where the
surface is not to be white washed, colour washed, distempered or painted; it shall be finished smooth
with a floating coat of neat cement or as required to match with the surrounding surfaces.
The holes shall be enumerated.
18.20.4 Rate
The rate shall include the cost of labour and materials required for all the operations described
above.
18.21 CUTTING HOLES IN R.C.C. FLOORS (UPTO 15 × 15 CM)

18.21.0 Square holes of size as specified shall be cut in R.C.C. floor and roofs for passing drain pipe
etc. Any damage to the adjoining portion or to any other item shall be made good as directed by the
Engineer-in-Charge. All the dismantled material shall be removed from the site.
18.21.1 Cement Concrete

After insertion of drain pipe etc. the hole shall be repaired with cement concrete 1:2:4 (1 cement:
2 coarse sand: 4 graded stone aggregate 20 mm nominal size) and the surface finished to match
with the existing surface. The top and bottom shall be finished properly to make the joint leak proof.
The specifications for cement concrete work and finishing etc. shall be the same as detailed under
relevant sub-heads.

Holes shall be enumerated.
18.21.3 Rate
The rate shall include the cost of labour and material required for all the operations described above
except the pipe which shall be paid for separately.
18.22 CUTTING CHASES IN MASONRY WALLS

18.22.1 Making Chases
Chases are made in the walls for housing G.I. Pipes etc.
I. Cutting of chases in one brick thick and above load bearing walls :
(i) As far as possible services should be planned with the help of vertical chases. Horizontal chases
should be avoided.
(ii) The depths of vertical chases and horizontal chases shall not exceed one third and one sixth of
the thickness of the masonry respectively.
(iii) When narrow stretches of masonry (or short lengths of walls) such as between doors and
windows, cannot be avoided, they should not be pierced with openings for soil pipes or waste
pipes or timber joints, etc. Where there is a possibility of load concentration, such narrow
lengths of walls shall be checked for stresses and high strength bricks mortar or concrete walls
provided, if required.
(iv) Horizontal chases when unavoidable should be located in the upper or lower one third of height
of storey and not more than three chases should be permitted in any stretch of a wall. No
continuous horizontal chase shall exceed one metre in length. Where unavoidable, stresses in
the affected area should be checked and kept within the permissible limits.
(v) Vertical chases should not be closer than 2 m in any stretch of a wall. These shall be kept away
from bearings of beams and lintels. If unavoidable, stresses in the affected area should be
checked and kept within permissible limits.
(vi) Masonry directly above a recess, if under than 30 cm (Horizontal dimension) should be supported
on lintel. Holes in masonry may be provided up to 30 cm width x 30 cm height without any lintel.
In the case of circular holes in masonry, no lintel should be provided up to 40 cm in diameter.
II. Cutting of chases in half brick load bearing walls

No chase shall be permitted in a half brick load bearing wall and as such no recessed conduits and
concealed pipes shall be provided in half brick thick load bearing walls.
III. Cutting of chases in half brick non-loading bearing walls

In case of non load bearing half brick walls services should be planned with the help of vertical
chases. Horizontal chases should be provided only when unavoidable.
IV. Cutting of chases in stone masonry walls

The provision (i) to (vi) under Sl. No. I are equally applicable to stone masonry walls also.
Note:
1. No inclined chase shall be permitted in brick masonry or stone masonry walls. In case inclined
chases are unavoidable these shall be cut with written approval of the Engineer-in-Charge, and
shall be repaired properly to his satisfaction. However, in half brick masonry wall, no inclined
chase will be permitted.
2. Chases shall be made by chiseling out the masonry to proper line & depth. Any damage to the
adjoining portion or to any other item shall be made good, as decided by the Engineer-in-Charge,
for which no extra payment shall be made. All dismantled material shall be removed from site.

18.22.2 Filling Chases
After G.I. Pipes etc. are fixed in chases, the chases shall be filled with cement concrete 1:3:6 (1 cement:
3 coarse sand: 6 graded stone aggregate 20 mm nominal size) or cement mortar 1:4 (1 cement: 4 coarse
sand) as may be specified or otherwise directed by the Engineer-in-Charge and made flush with the masonry
surface. The concrete surface shall be roughened with wire brushes to provide a key for plastering.
Chases shall be measured in running meter correct to a cm.
18.22.4 Rates
The rate shall include the cost of labour the materials involved in all the operations described above
excluding the cost of providing pipes etc. which shall be paid separately.
18.23 CP BRASS BIB COCK

The CP brass bib cock shall be conforming to IS : 8931. The body shall be of chromium plated copper
alloy and external and internal surfaces shall be clean, smooth and free from sand. The 15mm nominal bore
shall be designated by the nominal bore of the pipe outlet to which the bib cocks are normally fitted.
The dimensions of body for Bib Cock shall be as per table given to IS : 8931. Each bib cock shall be
legibly marked with the Manufacture’s name and trade mark.
18.24 CP BRASS LONG NOSE BIB COCK

The CP brass long nose bib cock shall be conforming to IS standards. The body shall be of chromium
plated copper alloy and external and internal surfaces shall be clean, smooth and free from sand. The 15mm
nominal bore shall be designated by the nominal bore of the pipe outlet to which the bib cocks are normally
fitted.
The weight of long nose Bib Cock shall be less than 810 grams. Each bib cock shall be legibly marked
with the Manufacture’s name and trade mark.
18.25 CP BRASS LONG BODY BIB COCK

The CP brass long body bib cock shall be conforming to IS standards. The body shall be of chromium
plated copper alloy and external and internal surfaces shall be clean, smooth and free from sand. The 15mm
nominal bore shall be designated by the nominal bore of the pipe outlet to which the long body bib cocks are
normally fitted.
The weight of long body Bib Cock shall be less than 690 grams. Each bib cock shall be legibly marked
with the Manufacture’s name and trade mark.
18.26 CP BRASS STOP COCK (CONCEALED)

The CP brass stop cock shall be conforming to IS : 8931. The body shall be of chromium plated copper
shall be designated by the nominal bore of the pipe outlet to which the stop cocks are normally fitted.
The dimensions of body for stop Cock shall be as per table given to IS : 8931. Each stop cock shall be
18.27 CP BRASS ANGLE VALUE

A valve with the inlet and outlet at right angles to each other and is intended to facilitate servicing of water
fittings or appliances.
The CP brass angle valve shall be conforming to IS: 8931. The body shall be of chromium plated copper
shall be designated by the nominal bore of the pipe outlet to which the angle valves are normally fitted.
The dimensions of body for angle valve shall be as per table given to IS: 8931. Each angle valve shall be

18.28 CP BRASS EXTENSION NIPPLE
The body shall be of chromium plated copper alloy and external and internal surfaces shall be clean,
smooth and free from sand. The size of CP brass extension nipple shall be 15mm x 50mm.
18.29 PTMT BIB COCK

The PTMT (Poly-tetra Methylene Terepthalate) bib cock shall be of appropriate size as specified and
weight should not be less than as specified. External and internal surfaces shall be clean and smooth with
good finish. Its colour shall be uniform. Each fitting shall be legibly marked with the manufacture’s name and
trade mark. Teflon tape shall be used on threads while fixing to make them leak proof.
18.30 PTMT STOP COCK

The PTMT (Poly-tetra Methylene Terepthalate) stop cock shall be of appropriate size as specified and
18.31 PTMT PILLAR COCK

The PTMT (Poly-tetra Methylene Terepthalate) pillar cock shall be of appropriate size as specified and
18.32 PTMT PUSH COCK

The PTMT (Poly-tetra Methylene Terepthalate) push cock shall be of appropriate size as specified and
18.33 PTMT GRATING

The PTMT (Poly-tetra Methylene Terepthalate) grating shall be of appropriate size as specified. External
and internal surfaces shall be clean and smooth with good finish. Its colour shall be uniform. Each fitting shall
be legibly marked with the manufacture’s name and trade mark.
18.34 PTMT BALL COCK

The PTMT (Poly-tetra Methylene Terepthalate) ball cock shall be of appropriate size as specified and
weight should not be less than as specified .External and internal surfaces shall be clean and smooth with
18.35 PTMT ANGLE STOP COCK

The PTMT (Poly-tetra Methylene Terepthalate) angle stop cock shall be of appropriate size as specified
and weight should not be less than as specified. External and internal surfaces shall be clean and smooth
with good finish . Its colour shall be uniform. Each fitting shall be legibly marked with the manufacture’s name
and trade mark. Teflon tape shall be used on threads while fixing to make them leak proof.
18.36 PVC CONNECTION PIPE

The PVC connection pipe with PTMT nuts, collar and bush shall be conforming to IS: 1024. The standard
size of PVC connection pipe shall be designated by the nominal bore with length. A sample of each kind of
fitting shall be got approved from the Engineer-in-charge and supplies made according to the approved sample.
PVC connection pipe shall be enumerated and rate shall include the cost of material and labour involved in
fixing the same.

18.37 PTMT EXTENSION NIPPLE FOR WATER TANK PIPE
The standard size of PTMT extension Nipple for water tank pipe, fitting shall be designated by the
nominal bore weighing not less than prescribed in the item. A sample of each kind of fitting shall be got
approved from the Engineer-in-charge and supplies made according to the approved sample. PTMT extension
Nipple for water tank pipe shall be enumerated and rate shall include the cost of material and labour involved
in fixing the same.
18.38 DISINFECTING C.I WATER MAINS BY FLUSHING WITH WATER

Disinfecting C.I water mains of different diameter pipe by flushing with water containing bleaching powder
@0.5 gms per litre of water and cleaning the same with fresh water, operation to be repeated three times
including getting the sample of water from the disinfected main and shall be tested in the municipal laboratory
and final sample obtained shall confirm to the standards.
18.39 CHROME PLATED BRASS BATTERY BASED INFRARED SENSOR OPERATED PILLAR COCK
The chrome plated brass battery based infrared sensor operated pillar cock shall be of chromium plated
copper alloy and external and internal surface shall be clean, smooth and free from sand. The 15 mm nominal
bore shall be designated by the nominal bore of the pipe outlet to which the chrome plated brass battery
based infrared sensor operated pillar cock are normally fitted.
Each chrome plated brass battery based infrared sensor operated pillar cock shall be legibly marked with
the manufacture’s name and trade mark. Chrome plated brass battery based infrared sensor operated pillar
cock shall be enumerated and rate shall include the cost of material and labour involved in fixing the same.

APPENDIX A
TOLERANCES FOR CAST IRON (CENTRIFUGALLY CAST) PIPES

(Clause 18.3.10)
Dimensions Nominal diameter (DN) Tolerances in mm

(a) External diameter of barrel (DE) All diameters. ± 1/2f = ± (4.5 + 0.0015 DN)
(b) Internal diameter of socket (DI) All diameters. ± 1/3f = ± (3 ± 0.001 DN)
(c) Depth of socket (P) (1) Up to and including 600 mm ±5
(2) Over 600 mm and up to and ± 10
including 1000 mm
Note : (1) f is the caulking space of the joint in millimeters and is equal to 9 + 0.003 DN.
(2) The jointing tolerances applicable to rubber joints (mechanical or push in joints) shall be as
specified by their manufacturer and shall be within the tolerances specified above.
Tolerance on Thickness
Dimensions Tolerance in mm
(a) Wall thickness – (1 + 0.05 e)
(b) Flange thickness ± (2 + 0.05 b)
Where e = is the thickness of the wall in millimeters and
b = is the thickness of the flange in millimeters.
Tolerance on Length
Dimensions Tolerance in mm
(a) Socket and spigot, and plain ended pipes ± 25
(b) Flanged pipes ± 10

APPENDIX B
TOLERANCES FOR SPECIALS OF CAST IRON PIPES

(Clause 18.3.10.2)
Tolerances in Diameter
Dimension Nature of joint Nominal diameter (DN) Tolerance in mm

External diameter of spigot (DE) Lead joints All diameters ±1/2
f or ± (4.5 + 0.0015 DN)
Internal diameter of socket (DI) Lead joints All diameters ±1/3
f or ± (3 + 0.001 DN)
Depth of socket (P) Lead joints Up to and including 600 mm ±5
Over 600 mm up to and ± 10
including 1000 mm.
Over 1000 mm up to and ± 15
including 1500 mm.
Tolerances on Thickness
Dimension Tolerance in mm
Wall thickness – (2 + 0.05 e)
Flange thickness ± (3 + 0.05 b)
Where e = the standard thickness of the wall in millimeters, and

b = the standard thickness of the flange in millimeters.
Tolerance on Lengths
Type of fitting Nominal diameter Tolerance in mm

Socket fittings and flange spigot Up to and including 450 mm ± 20
pieces Over 450 mm ± 20 – 30
Flanged fittings All diameters ± 10

APPENDIX C
PARTICULARS OF MEDIUM GRADE G.I. PIPES
(Clause 18.3.11.3)
Nominal bore Dimension of pipes Weight of pipe

Outer diameter Thickness Plain end Screwed end
Max Min socket
(mm) (mm) (mm) (mm) (kg/m) (kg/m)
6 10.6 9.8 2.0 0.404 0.407

8 14.0 13.2 2.3 0.641 0.645
10 17.5 16.7 2.3 0.839 0.845
15 21.8 21.0 2.6 1.21 1.22
20 27.3 26.5 2.6 1.56 1.57
25 34.2 33.3 3.2 2.41 2.43
32 42.9 42.0 3.2 3.10 3.13
40 48.8 47.9 3.2 3.56 3.60
50 60.8 59.7 3.6 5.03 5.10
65 76.6 75.3 3.6 6.42 6.54
80 89.5 88.0 4.0 8.36 8.53
100 115.0 113.1 4.5 12.2 12.50
125 140.8 138.5 4.8 15.90 16.40
150 166.5 163.9 4.8 18.90 19.50
Tolerance in Thickness and Weight
A) Thickness
1. Butt welded medium tubes + not limited

– 10 per cent
2. Seamless tubes + not limited

– 12.5 per cent
B) Weight
1. Single tube (light series) + 10 percent

- 8 per cent
2. Single tube (medium and heavy series) ± 10 per cent
3. For quantities per load of 10 tonnes, min (light series) ± 5 per cent
– 8 per cent
4. For quantities per load of 10 tonnes, min (medium and heavy series) ± 7.5 per cent

APPENDIX D
PROC
CEDURE FOR PRESSURE TEST
(Clause 18.5.6)
1. Each valved section of the pi

pipe shall be slowly filled with water and all air sha
all be expelled from
the pipe through hydrants and blow
low-offs. If these are not available at high places,, necessary tapping
may be made at points of highestt elevation before the test is made and plugs inse erted after the tests
have been completed.
2. If the trench has been partiatially back-filled the specified pressure based on the
th elevation of the
lowest point of the line or section uunder test and corrected to the elevation of the test
te gauge, shall be
applied by means of a pump conne nected to the pipe in a manner satisfactory to the Engineer-in-Charge.
En
The duration of the test shall not be less than 5 minutes.
3. Examination under Pressu ure: All exposed pipes, fittings, valves, hydrants and
an joints should be
carefully examined during the ope en-trench test. When the joints are made with lead,le all such joints
showing visible leaks shall be recacaulked until tight. When the joints are made with th cement and show
seepage or slight leakage, such joijoints shall be cut out and replaced as directed by y the authority. Any
cracked or defective pipes, fittings,
s, valves or hydrants discovered in consequence of o this pressure test
shall be removed and replaced by ssound material and the test shall be repeated until til satisfactory to the
Engineer-in-Charge.
4. If the trench has been back-ffilled to the top, the section shall be first subjected
ed to water pressure
normal to the area and the expose sed parts shall be carefully examined. If any defec ects are found, they
shall be repaired and the pressure re test repeated until no defects are found. The duration
d of the final
pressure tests shall be at least one
e hour.
Procedure for Leakage Test
5. Leakage is defined as the qu

quantity of water to be supplied into the newly laid pipe,
p or any valved
section thereof, necessary to maint
ntain the specified leakage test pressure after the pipe
p has been filled
with water and the air expelled.
3
No pipe installation shall be acc
ccepted until the leakage is less than the number of cm /h determined
by the formula:
ql = ND P
3.3
3
Where ql = the allowable
le leakage in cm /h.
N = number of join
oints in the length of the pipe line.
D = diameter in m
mm, and
P pressure during the leakage testing kg/cm2.
=the average test p
6. Variation from Permissible Leakage: Should any test of pipe laid in position n discloses leakage
greater than that specified in Para
a 5 the defective joints shall be repaired until the leakage
le is within the
specified allowance.

APPENDIX E
GUIDELINES FOR STORAGE AND INSTALLATION OF CPVC PIPES
E-1 STORAGE
CPVC pipes of all sizes are packed in polyethylene packing rolls and both the ends of the packed
roll are sealed with air bubble film cap in order to provide protection during handling and transportation.
After packing, the whole bunch of pipes is tightened with polypropylene/ HDPE strapping. Each role is
then marked with size/type of the pipe, lot number and quantity. The packed pipe rolls are stored in
their respective racks in properly covered storage area. Apart from providing protection during handling
and transportation, the packing rolls also protect the pipe from ultra violet rays.
E-2 INSTALLATION GUIDELINES
E-2.1 Visually inspect pipe ends before making the joint. Use of a chamfering tool will help identify and
crakes, as it will catch on to any crack.
E-2.2 Pipe may be cut quickly and efficiently by several methods. Wheel type plastic tubing cutters are
preferred. Ratchet type cutter or fine tooth saw are another options. However, when using the ratchet
cutter be certain to score the exterior wall by rotating the cutter blade in circular motion around the
pipe. Do this before applying significant downward pressure to finalize the cut. This step leads to a
square cut. In addition, make sure ratchet cutter blades are sharp. Cutting tubing as squarely as
possible provides optimal bonding area within a joint.
E-2.3 Burrs and filings can prevent proper contact between the tube and fittings during the assembly,
and should be removed from the outside and inside of the tube. A chamfering tool is preferred, but a
pocket knife or file is also suitable for this purpose.
E-2.4 Use only CPVC cement jointing. Use CPVC cement, which is fully recommended by the
manufacturer.
E-2.5 When using adhesive solution/solvent cement be certain of proper ventilation.
E-2.6 When making a join, apply a heavy, even coat of cement to the pipe end. Use the same
applicator without additional cement to apply a thin coat inside the fitting socket. Too much cement can
cause clogged waterways. Do not allow excess cement to puddle in the fitting and pipe assembly. This
could result in a weakening of the pipe wall and possible pipe failure when the system is pressurized.
E-2.7 Rotate pipe one-quarter to one-half turn while inserting it into the fitting socket and remove the
excess adhesive solution/solvent cement from the joint with clean rag.
E-2.8 When making a transition connection to metal threads, use a special transition fitting or CPVC
male threaded adapter whenever possible. Do not over-torque plastic threaded connections. Hand tight
plus one-half turn should be adequate.
E-2.9 Hang or strap CPVC systems loosely to allow for thermal expansion. Do not use metal straps
with sharp edges that might damage the tubing.
E- 2.10 CPVC stub outs for lavatories, closets and sinks are appropriate. However, on areas where
there is a likelihood that movement or impact abuse will occur, metal pipe nipples may be amore
appropriate stub-out material. Showerheads, tub spouts and outside still cocks are examples.
E-2.11 When connected to a gas water heater, CPVC tubing should not be located within 50 cm of the
flue. For water heaters lacking reliable temperature control, this distance may be increased up to 1 m a
metal nipple or flexible appliance connector should be utilized. This measure eliminates the potential
for damage to plastic piping that might result from excessive radiant heat from the flue.

APPENDIX F
SAMPLING AND CRITERIA FOR CONFORMITY OF CPVC PIPES

(Clause 18.9.6)
F-1 ACCEPTANCE TESTS

F-1.1 Acceptance test are carried out on samples selected from a lot for the purpose of acceptance
of the lot.
F-1.2 Lot
All CPVC pipes in a single consignment of the same class, same size and manufactured under
essentially similar conditions shall constitute a lot.
F-1.3 For ascertaining conformity of the lot to the requirements of the specification, samples shall be
tested from each lot separately.
F-1.4 Visual and Dimensional Requirements

F-1.4.1 The number of test samples to be taken from a lot shall depend on the size of the lot and the
outside diameter of the pipe, and shall be in accordance with Table F-1.
TABLE F-1
Scale of Sampling of Visual Appearance and Dimensional Requirements
(Clause F-1.4.1 and F-1.4.3)
Sl. Number of pipes in Sample Sample size Cumulative Acceptance Rejection

No. the lot number sample size number number
(1) (2) (3) (4) (5) (6) (7)
(i) Up to 1000 First 13 13 0 2
Second 13 26 1 2
(ii) 1001 to 3000 First 20 20 0 2
Second 20 40 1 2
(iii) 3001 to 10000 First 32 32 0 3
Second 32 64 3 4
(iv) 10001 & above First 50 50 1 4
Second 50 100 4 5
F-1.4.2 These pipes shall be selected at random from the lot and in order to ensure the randomness
of selection, a random number table shall be used. For guidance and use of random number tables,
IS-4905 may be referred to. In the absence of a random number table, the following procedure may
be adopted:
Starting from any pipe in the lot, count them as 1, 2, 3, etc, up to r and so on, where r is the
integral part of N/n, N being the number of pipes in the lot, and n the number of pipes in the sample.
Every rth pipe so counted shall be withdrawn so as to constitute the requires sample size.
F-1.4.3 The number of pipes given for the first sample in col. 4 of Table F-1, shall be taken from the
lot and examined for visual and dimensional requirements given in Table 18.16 and 18.9.4.1. A pipe
failing to satisfy any of these requirements shall be considered as defective. The lot shall be deemed
to have satisfied these requirements, if the number of defectives found in the firm sample is less than
or equal to the corresponding acceptance number given in col. 6 of Table F-1. The lot shall be
deemed not to have met these requirements, if the number of defectives found in the first sample is
greater than or equal to the corresponding rejection number given in col. 7 of Table F-1. If, however,
the number of defectives found in the first sample lies between the corresponding acceptance and
rejection numbers given in cols. 6 and 7, a second sample of the size given in col. 4 shall be taken

and examined for the requirements. The lot shall be considered to have satisfied these requirements.
The lot shall be considered to have satisfied these requirements if the cumulative sample is less than
or equal to the corresponding acceptance number given in col. 6, otherwise not.
F-1.5 Reversion Test

F-1.5.1 The lot, having satisfied visual and dimensional requirements, shall be tested for reversion
as given in 18.9.4.4.
F-1.5.2 For this purpose, the number of pipes given for the first sample in col. 4 of Table F-2 shall be
taken from the lot. The sample pipe failing the reversion test shall be considered as defective. The
lot shall be deemed to have met the requirements given in this specification for the reversion test, if
the number of defectives found in the first sample is less than or equal to the corresponding acceptance
number given in col. 6. This lot shall be deemed not to have met these requirements, if the number
of defectives found in the first sample is greater than or equal to the corresponding rejection number
given in col. 7 if, however, the number of defectives in the first sample lies between the corresponding
acceptance and rejection numbers given in col. 6 and col. 7, a second sample of size given in col. 4
shall be taken and examined for the requirements. The lot shall be considered to have satisfied the
requirements, if the number of defectives found in the cumulative sample is less than or equal to the
corresponding acceptance number given in col. 6, otherwise not.
TABLE F-2
Scale of Sampling for Reversion, Vicat Softening Temperature and Density Test
(Clause F-1.5.2, F-1.6.2 and F-1.7.2)
Sl. No. Number of pipes in the Sample Sample Cumulative Acceptance Rejection
lot number size sample size number number
(1) (2) (3) (4) (5) (6) (7)
(i) Up to 1000 First 5 5 0 2
Second 5 10 1 2
(ii) 1001 to 3000 First 8 8 0 2
Second 8 16 1 2
(iii) 3001 to 10000 First 13 13 0 2
Second 13 26 1 2
(iv) 10001 & above First 20 20 0 3
Second 20 40 3 4
F-1.6 Vicat Softening Test

F-1.6.1 The lot, having satisfied visual and dimensional requirements shall be tested for Vicat softening
temperature as given in 18.9.4.5.
F-1.6.2 For this purpose, the procedure adopted for sampling and criteria for conformity shall be the
same as that for reversion under F-1.5.2 using Table F-2.
F-1.7 Density
F-1.7.1 The lot, having satisfied the visual and dimensional requirements, shall be tested for density
as given in 18.9.4.6.
F-1.7.2 For this purpose, the procedure adopted for sampling and criteria for conformity shall be the
same as that for reversion under F-1.5.2 using Table F-2.
F-1.8 Resistance to External Blow at 0°C

F-1.8.1 The lot, having been found satisfactory according to F-1.4, F-1.5, F-1.6 and F-1.7 shall be
tested for resistance to external blow at 0°C as given in 18.9.5.3.

F-1.8.2 For this purpose, the procedure adopted for sampling and criteria for conformity shall be as
specified in Table 18.18 and Table F-3.
TABLE F-3
Scale of Sampling for Resistance to External Blow at 0°C
Sl. No. Number of pipes in Sample Sample Cumulative Acceptance Rejection
the lot number size sample size number number
(1) (2) (3) (4) (5) (6) (7)
(i) Up to 3000 First 3 3 0 2
Second 3 6 1 2
(ii) 3001 to 10000 First 3 5 0 2
Second 5 10 1 2
(iii) 10000 & above First 8 8 0 2
Second 8 10 1 2
F-1.9 Internal Hydrostatic Pressure Test (Acceptance Test) F-1.9.1 The lot having been found
satisfactory according to F-1.4, F-1.5, F-1.6, F -1.7 and F-1.8 shall be subjected to the requirements
of the acceptance test for internal hydrostatic pressure as given in 18.9.5.1 and Table 18.17 Sl.No.
(i).The number of pipes to be taken from the lot shall depend on the size of the lot and shall be
according to Table F-4.
TABLE F-4
Scale of Sampling for Internal Hydrostatic Test
(Clause F-1.9.1 and F-1.9.3)
Sl. No. Number of pipes in the lot Sample size Acceptance number
(1) (2) (3) (4)
(i) Up to 3000 2 0
(ii) 3001 to 10000 3 0
(iii) 10000 & above 5 0
F-1.9.2 The pipes shall be taken at random from the lot. In order to ensure the randomness of
selection, procedures given in IS 4905 may be followed.
F-1.9.3 Number of Tests and Criteria for Conformity

The number of test samples shall be as given in Table F-4. The lot shall be considered to have
satisfied the requirements for this test, if the number of test samples failing in this requirement is
equal to the corresponding acceptance number given in column 4 of Table F-4.
F-2 TYPE TESTS

F-2.1 Type tests are intended to prove the suitability and performance of a new composition or a new
size of pipe. Such tests, therefore, need to be applied only when a change is made in polymer
composition or when a new size of pipe is to be introduced. Type test for compliance with 18.9.4.2,
18.9.4.3, 18.9.5.1 (Type test only) and 18.9.5.4 shall be carried out.
F-2.1.1 Verification of Malfunction Temperature Tmal

For this test, the manufacturer to the testing authority one assembly, selected preferably from a
regular production lot.
F-2.1.2 Opacity
For this test, the manufacturer or the supplier shall furnish to the testing authority one sample of
the pipe of the thinnest wall section, selected preferably from a regular production lot.

F- 2.1.2.1 The sample so selected shall be tested for compliance with requirements for opacity as
given in 18.9.4.2.
F-2.1.2.2 If the sample passes the requirements of the opacity test, the type of the pipe under
consideration shall be considered to be eligible for approval, which shall be valid for a period
of one year.
F-2.1.2.3 In case the sample fails in the test, the testing authority, at its discretion, may call for a
fresh sample and subject the same to the opacity test. If the sample passes the repeat test, the type
of pipe under consideration shall be considered eligible for approval. If the sample fails in the repeat
test, the type of pipe shall not be approved. The manufacturer or the supplier may be asked to
improve the design and re-submit the product for type approval.
F-2.1.2.4 At the end of the validity period (normally one year) or earlier, if necessary, the testing
authority may call for a fresh sample for opacity test for the purpose of type approval.
F-2.1.3 Test for Effect on Water

For this type test, the manufacturer or the supplier shall furnish to the testing authority three
samples of the smallest size of pipe taken from each machine (selected preferably from a regular
production lot).
F-2.1.3.1 Three samples so selected shall be tested for compliance with the requirements for effect
on water as given in 18.9.4.3.
F-2.1.3.2 If all three samples pass the requirements for effect on water, the type test of the pipe
under consideration shall be considered to be eligible for approval, which hall be normally valid for a
period of one year.
F-2.1.3.3 In case any of the samples fails in this test, the testing authority, at its discretion, may call
for fresh samples not exceeding the original number, and subject them to the test for effect on water.
If, in the repeat test, no single failure occurs, the type of pipe under consideration shall be considered
eligible for type approval. If any of the samples fails in the repeat test, the type of pipe shall not be
approved. The manufacturer or the supplier may be asked to improve the design and resubmit the
product for type approval.
authority may call for fresh samples for effect on water test for the purpose of type approval.
F-2.1.4 Internal Hydrostatic Pressure Test (Type Test) and thermal Stability
For this type test, the manufacturer or the supplier shall furnish to the testing authority, three
samples of pipes of different diameters and different classes (selected preferably from a regular
production lot).
F-2.1.4.1 Three samples so selected shall be tested for compliance with the requirements of type
test given in Table 18.9.4.3.
F-2.1.4.2 If all the three samples pass the requirements of the quality test, the type of pipe under
consideration shall be considered to be eligible for type approval which shall be normally valid for a
period of one year.
F-2.1.4.3 In case any of the samples fail in this test, the testing authority, at its discretion, may call for
fresh samples not exceeding the original number and subject them to the type test. If, in the repeat
test, no single failure occurs, the type of pipe shall be considered for type approval. If any of the
samples fails in the repeat tests, the type of pipe shall not be approved. The manufacturer or the
supplier may be asked to improve the design and resubmit the product for type approval.

authority may call for fresh samples for type test for the purpose of type approval.
F-2.1.5 Tensile Strength Test (Type Test)

For this type test, the manufacturer or the supplier shall furnish to the testing authority, five samples
of pipe of different diameters and different class (selected preferably from a regular production lot).
F-2.1.5.1 Five samples so selected shall be tested for compliance with the requirements of type test
given in 18.9.5.4.
F-2.1.5.2 If all the five samples pass the requirement of the quality test, the type test of pipe under
consideration shall be considered to be eligible for type approval which shall be normally valid for a
period of one year.
F-2.1.5.3 In case any of the samples fails in this test, the testing authority, at its discretion, may call
for fresh samples not exceeding the original numbers and subject them to the type test. If, in the
repeat test no single failure occurs, the type of pipe shall be considered for type approval. If any of
the samples fail in the repeat tests, the type of pipe shall not be approved. The manufacturer or the
supplier may be asked to improve the design and resubmit the product for type approval.
authority may call for fresh samples for type test for the purpose of type approval.

BALL VALVE (ASSEMBLY)
Sub Head : Water Supply
Clause : 18.3.1
Note : The shapes of the component parts are only illustrative but the dimensions and minimum requirements,
where specified, are binding.
Fig. 18.1 : Ball Valve (Assembly)

FITTINGS & SPECIALS
Clause : 18.3.9

Fig. 18.2 : Fittings & Specials

BIB TAP & STOP VALVE
Clause : 18.3.2
Dimensions A B C D E F G H J K L M N P Q R S T U V W Lift of
+0.0 wash
-0.5 er
plate
(with
wash
er in
positi
on)
Nominal Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min. Min.
sizes
8 47.8 13.3 7.8 16.5 6.3 2.0 7.9 7.0 3.8 10.0 M20x1.5 14.3 2.8 6.5 2.4 11.0 4.7 1.6 15.2 19.5 7 3.5
10 54.0 14.0 9.4 18.7 7.5 2.0 9.5 9.5 4.7 11.5 M20x1.5 15.9 3.2 9.0 3.2 11.4 7.9 2.0 20.8 23.3 7 4
15 54.0 14.0 9.4 19.0 7.5 2.0 9.5 11.0 5.6 11.5 M24 1.5 19.0 3.2 13.0 4.1 15.0 9.5 2.0 25.6 28.3 9 4.5
20 60.4 15.7 10.9 20.1 8.9 2.5 11.1 12.5 6.4 13.5 M30x1.5 25.4 4.0 18.0 4.9 16.3 10.3 2.0 30.5 33.0 10.5 6
25 66.8 18.0 12.5 23.0 10.1 2.5 12.7 13.0 7.1 17.0 M39x1.5 33.3 4.0 23.0 4.9 19.1 11.0 2.8 37.6 42.4 11.5 7
32 74.6 20.5 14.1 30.9 11.4 2.5 14.3 16.0 7.8 19.0 M48x1.5 40.1 4.3 30 5.9 21.4 12.7 3.2 47.2 52.1 13.5 9.5
40 82.5 22.0 15.7 33.3 12.7 2.5 15.9 17.5 8.6 20.5 M56x1.5 47.7 5.5 36 6.6 21.4 14.3 3.2 56.4 58.5 13.5 11
50 95.0 25.3 17.3 35.9 14.0 2.5 17.4 17.5 12.5 26.0 M72x1.5 63.5 6.3 46 8.3 25.1 15.9 4.0 70.1 71.5 16.5 14.5
Note 1 : Length of thread R includes cut back under hexagon, if any.

Note 2 : The values of K are for core diameter.
Note 3 : The diameter of U and V are for face to face.
Note 4 : The dimension F is packing space.
Fig. 18.3 : Bib Tap & Stop Valve

COCKS VALVES & METER
Clause : 18.3.15

All Dimensions are in MM
Fig. 18.4 : Cocks Valves & Meter

UNDERGROUND FIRE HYDRANT, SLUICE-VALVE GATE
Clause : 18.3.4
No Description Mat. Mat. Specification

1 Body C.I. IS 210-1972 FG-200
2 Valve Seat G.M. IS 318-1981 LTB-2
3 Washer Rubber IS 937-1981
4 Valve G.M. IS 318-1981 LTB-2
5 Spindle Nut G.M. IS 318-1981 LBT-2
6 Bonnet C.I. IS 210-1978 FG-200
7 Spindle Brass IS 319-1989
8 Gland C.I. IS 210-1978 FG-200
9 Grush Screw (12 mm) M.S. IS 6094-1981
10 Spindle Cap C.I. IS 210-1978 FG-200
11 Drain Bolt M.S. -
12 Outlet G.M. IS 318-1981 LTB-2
13 Cap C.I. IS 210-1978 FG-200
14 Chain Gal. MS -
15 Nut and Bolt M.S. -
TOLERANCES AS PER IS 2102-1962
Fig. 18.5 : Underground Fire Hydrant, Sluice-Valve Gate

MASONRY CHAMBERS & SURFACE BOXES
Clause : 18.3.14

Fig. 18.6 : Masonry Chambers & Surface Boxes

MASONRY CHAMBERS & SURFACE BOXES (Contd.)
Clause : 18.3.14

Fig. 18.7 : Masonry Chambers & Surface Boxes (Contd.)

THRUST BLOCKS
Clause : 18.4.6
Fig. 18.8 : Thrust Blocks

HYDROSTATIC TESTS
(END CLOSURE FOR PIPES)

Clause : 18.4.8

Fig. 18.9 : Hydrostatic Test (End Closure for Pipes)

SUB HEAD : 19.0
DRAINAGE
1009
CONTENTS
19.2 Pipes and Specials 1019
19.2.1 Glazed Stone Ware Pipes & Fittings 1019
19.2.2 Cement Concrete Pipes 1023
19.2.3 Cast Iron (Centrifugally Cast) Pipes & Specials 1026
19.2.4 Road Gully Grating 1026
19.3 Manhole Covers & Frames 1026
19.4 Manholes 1029
19.5 Drop Connection 1031
19.6 Open Surface Drain 1032
19.7 Road Gully Chamber with Grating 1032
19.8 Brick Masonry Gully Trap 1033
19.9 Septic Tank 1033
19.10 Soak Pits 2.5 m dia x 3 m deep 1034
19.11 Soak Pit 1.2 x 1.2 x 1.2 m 1035
19.12 Dispersion Trench 1035
19.13 Desludging of Septic Tanks 1035
19.14 Dismantling of old S.W. Pipes 1035
19.15 6 mm thick plastic encapsulated M.S. Foot rest 1035
19.16 Replacement of M.S. Foot Rests In Manholes 1036
1011 SUB HEAD 19.0 : DRAINAGE

19.17 Raising of Manhole Cover and Frame Slab 1036
19.18 Inspection Chamber 1037
19.19 Non Pressure NP-3 Class (Medium Duty)/ NP-4 1038

Class (Heavy Duty) R.C.C. Pipes
Appendix -I Dimensional Requirements of Concrete Pipes 1042
Appendix -IA Design Requirement of Reinforced Concrete Collar 1044

for Pipe Of Class NP-2
Appendix -IB Design and Strength Test Requirements of Concrete 1045

Pipes of Class NP2- Reinforced Concrete,
Light Duty, Non-pressure Pipes
Appendix -IC Design Requirements of Reinforced Concrete 1046

Collars for Pipes of Class NP3 and NP4
Appendix -ID Design and Strength Test Requirements of Concrete 1047

Pipes of Class NP3-Reinforced Concrete, Medium
Duty, Non-pressure Pipes
Appendix -IE Design and Strength Test Requirements of Concrete 1048

Duty, Non-pressure Pipes made by Vibrated Casting
Process
Appendix -IF Design and Strength Test Requirements of Concrete 1049

Duty, Non-pressure Pipes
Appendix -IG Design and Strength Test Requirements of Concrete 1050

Pipes of Class NP4-Reinforced Concrete, Heavy
Duty, Non-pressure Pipes made by Vibrated Casting
Process
Appendix -II Recommended Sizes of Septic Tanks 1052
Fig. 19.1 Flushing Tank 1053
Fig. 19.2 Gully Trap 1054
Fig. 19.3 Manhole 1055
Fig. 19.4 Manhole (Contd.) 1056

Fig. 19.8 Manhole with Drop Connections 1060
Fig. 19.9 Bedding of Pipes 1061
Fig. 19.10 Joints of Concrete Pipes 1062
Fig. 19.11 Bedding/Encasing Stone Ware Pipes 1063
Fig. 19.12 Brick Masonry Open Surface Drains 1064
Fig. 19.13 R.C.C. Road Gully Grating 1065
Fig. 19.14 Road Gully Chamber 1066
Fig. 19.15 Septic Tank 1067
Fig. 19.16 Septic Tank (Contd.) 1068
Fig. 19.17 Soak Pit 1069
Fig. 19.18 Dispersion Trench 1070
Fig. 19.19 6mm thick Plastic Encapsulated M.S. Footrest as 1071

per IS:10910
Fig. 19.20 610X455 with Light Duty Cover 1072
Fig. 19.21 700X500 with Medium Duty Cover 1073
Fig. 19.22 850X600 with Medium Duty Cover 1074


S. No. IS No. Subject
1. IS 458 Pre-cast Concrete Pipes (with and without reinforcement).
2. IS 651 Specification for Salt Glazed Stoneware Pipes and Fittings.
3. IS 783 Code of Practice for Laying Concrete Pipes
4. IS 1726 Specification for Cast Iron Manhole Covers and Frames
5. IS 1729 Cast Iron /Ductile Iron Drainage Pipes and Pipe Fittings Socket
and Spigot Series for Over-ground Non-pressure Pipe Line.
6. IS 4127 Code of Practice for Laying of Glazed Stone Ware Pipes
7. IS 4885 Specifications for Sewer Bricks
8. IS 12592 Pre-cast Concrete Manhole Covers and Frames - Specifications
9. IS 3114 Code or Practice for laying of Cast iron pipes.
10. IS 5961 Specification for cast iron grating for drainage purpose.
11. IS 2470 (Part -1) Code of practice for Installation of septic tank : Part 1 Design criteria
and construction

19.0 DRAINAGE
19.0 TERMINOLOGY
Benching (Fig. 19.8): The sloped floor of a manhole or an inspection chamber on both sides and
above the top of the channel.
Channel: The open waterway through which sewage, storm water or other liquid waste flow at the
invert of a manhole or an inspection chamber.
Cleaning Eye (Fig. 19.8): An access opening having a removable cover to enable obstructions to
be cleared by means of a drain rod.
Connections: The junction of a foul water drain, surface water drains with public sewer, cesspool
soak-way or other water courses.
Flushing Tank (Fig. 19.1) : Tank used to flush the sewer lime/manholes.
Curb, Kerb: The stone margin of a side walk.
Dispersion Trench: A trench in which open jointed pipes surrounded by coarse aggregate media
and overlaid by fine aggregate, are laid. The effluent from septic tank gets dispersed through the
open joints and is absorbed in the surrounding soil.
Depth of Manhole: The vertical distance from the top of the manhole to the outgoing invert of the
main drain channel.
Drain: A line of pipes including all fittings and equipment, such as manholes traps, gullies and floor
traps used for the drainage of a building, or a number of buildings or yards appurtenant to the
buildings, within the same cartilage. Drain shall also include open channels used for conveying
surface water.
Drainage: The removal of any liquid by a system constructed for the purpose.
Drop Connection (Fig. 19.8): A branch drain of which the last length of piping of the incoming
drain, before connection to the sewer, is vertical.
Drop Manhole (Fig. 19.8): A manhole incorporating a vertical drop for the purpose of connecting a
sewer or drain at high level to one at lowers level.
Effluents
(a) Tank Effluent: The supernatant liquid discharge from a septic tank.
(b) Filter Effluent: The liquid discharged from a biological filter.
Gully Chamber (Fig. 19.2): The chamber built of masonry around a gully trap, for housing the
same.
Gully Trap (Fig. 19.2): A trap water seal provided in a drainage system in a suitable position to
collect waste water from the scullery, kitchen sink, wash basins, baths and rain water pipes.
Haunching (Fig. 19.11): Concrete bedding with additional concrete at the sides of the pipe.

Junction Pipe: A pipe incorporating one or more branches.
Invert: The lowest point of the interior or a sewer or drain at any cross action.
Inspection Chamber: A water tight chamber constructed in any house drainage system which
takes wastes from gully traps and disposes off to manhole with access for inspection and maintenance.
Interceptor Manhole (Interceptor Chamber): A manhole incorporating an intercepting trap,

and providing means of access thereto and equipped with a fresh air inlet on the upstream side
of the trap.
Manhole (Manhole Chamber): Any chamber constructed on a drain or sewer so as to provide

access thereto for inspection testing or the clearance of obstruction.
Rest Bend (Duck Foot Bend): A bend supported in a vertical position by a foot formed at its base.
Saddle: A purpose made fitting, so shaped as to fit over a hole cut in a sewer or drain, and used to
form connections.
Soffit: The highest portion of the interior of a sewer or drain at any cross-section.
Soil Waste: The discharge from water closets, urinals, slope sinks, stable or cowshed gullies and
similar appliances.
Soil Pipe: Which receives the discharges from soil fitments, such as water closets urinals, and slope
sinks.
Sullage Waste Water: Spent water from baths, wash basins kitchen sinks, and similar appliances
which does not contain human or animal excreta.
Sewer: A closed drain carrying night soil and other water borne waste.
Surface Water Drain: A drain conveying surface water including storm water.
Surface Water: The run off from precipitation, other water that flows over surface of the ground.
Sub Soil Water: Water occurring naturally below the surface of the ground.
Sludge: The settled solid matter in semi solid condition.
Soak Pit (Seepage Pit Soak Way) (Fig. 19.17) : A pit through which effluent is allowed to seep or
leach into the surrounding soil.
Septic Tank (Fig. 19.15 & 19.16) : A water tight single storied tank in which sewage is retained
sufficiently long to permit sedimentation of suspended solids and partial digestion of settled sludge
by anaerobic bacteria.
Scum: The greasy and other substances floating on the surface of sewage.

Vent Pipe: A pipe line installed to provide flow of air to or from a drainage system or to provide
circulation of air within such system to protect trap seals from siphonage and back flow.
Waste Water: The discharge from wash basins, sinks and similar appliance, which does not contain
human excreta.

19.1.1 In designing a drainage system for building(s), the aim shall be to provide a self cleansing conduit for
the conveyance of soil, waste, surface or sub-surface waters and for the removal of such wastes speedily and
efficiently to a sewer or other outlet, without risk of nuisance and hazard to health.
19.1.2 The discharge of water through a domestic drain is intermittent and limited in quantity and therefore,
small accumulations of solid matter are liable to form in the drains between the building and the public sewer.
There is usually a gradual shifting of these deposits as discharges take place. Gradients shall be sufficient to
prevent these temporary accumulations building up and blocking the drains.
19.1.3 Normally, the sewer shall be designed for discharging three times the dry weather flow flowing half-full
with a minimum self cleansing velocity of 0.75 metre per second. The approximate gradients which give this
velocity for the sizes of pipes likely to be used in building drainage and the corresponding discharges when
flowing half-full are given in Table 19.1. The sizes and slopes shall conform to Local Municipal Bye-laws.
19.1.4 In cases, where it is practically not possible to conform to the minimum gradients, a flatter gradient
may be used but the minimum velocity in such cases shall on no account be less than 0.61 metres per
second.
19.1.5 On the other hand, it is undesirable to employ gradients giving velocity of flow greater than 2.4 metres
per second. Where it is unavoidable, cast iron pipes shall be used. The approximate gradients which give a
velocity of 2.4 metres per second for the various sizes of pipes and the corresponding discharge when flowing
half-full are given in Table 19.1.
TABLE 19.1
Gradients for Sewers
Diameter Minimum Gradient Maximum Gradient
mm Gradients Discharge Gradients Discharge
cum/Min. cum/Min.
100 1 in 57 0.18 1 in 5.6 0.59
150 1 in 100 0.42 1 in 9.7 1.32
200 1 in 145 0.73 1 in 14 2.4
230 1 in 175 0.93 1 in 17 2.98
250 1 in 195 1.10 1 in 19 3.60
300 1 in 250 1.70 1 in 24.5 5.30
19.2 PIPES AND SPECIALS

19.2.1 Glazed Stone Ware Pipes and Fittings
All pipes with spigot and socket ends and fittings shall conform to class SP1 of IS 651. These shall be
sound, free from visible defects such as fire cracks or hair cracks. The glaze of the pipes shall be free from
crazing. The pipes shall give a sharp clear tone when struck with a light hammer. There shall be no broken
blisters. The thickness of pipes shall be as given in the Table 19.2.

TABLE 19.2
Stoneware Pipes
Internal Diameter (mm) Mean Thickness of the Barrel and Socket (mm)
100 12
150 15
200 16
230 19
250 20
300 25
350 30
400 35
450 37
The length of pipes shall be 60, 75, 90 cm exclusive of the internal depth of the socket. The pipes
shall be handled with sufficient care to avoid damage to them.
19.2.1.1 S.W. Gully Trap (Fig. 19.2): Gully traps shall conform to IS 651. These shall be sound, free
from visible defects such as fire cracks, or hair cracks. The glaze of the traps shall be free form crazing.
They shall give a sharp clear tone when struck with light hammer. There shall be no broken blisters.
Each gully trap shall have one C.I. grating of square size corresponding to the dimensions of inlet
of gully trap. It will also have a water tight C.I. cover with frame inside dimensions 300 x 300 mm the
cover weighing not less than 4.50 Kg and the frame not less than 2.70 Kg. The grating, cover and
frame shall be of sound and good casting and shall have truly square machined seating faces.
19.2.1.2 Laying and Jointing Stone Ware Pipes : For all sewers and drains, glazed stoneware
pipes shall be used as far as possible in preference to other types of pipes. These are suitable,
particularly where acid effluents or acid sub-soil conditions are likely to be encountered.
(i) Trenches: Specifications described in 19.2.2.1 shall apply, as far as possible.
The trench shall be so dug that the pipe can be laid to the required alignment and at the
required depth. When the pipe line is under a roadway, a minimum cover of 90 cm is
recommended for adoption, but it may be modified to suit local conditions. The trench shall
be excavated only so far in advance of pipe laying as specified by the Engineer-in-Charge.
The trench shall be so shored and drained that the workmen may work therein safely and
efficiently. The discharge of the trench dewatering pumps shall be conveyed either to
drainage channels or to natural drains.
The excavation shall be carried out with manual labour or with suitable mechanical equipment
as approved by the Engineer-in-Charge.
Unless otherwise specified by the Engineer-in-Charge, the width at bottom of trenches for
different diameters of pipes laid at different depths shall be as given below:—
(a) For all diameters, up to an average depth of 120 cm, width of trench in cm = diameter
of pipe + 30 cm.
(b) For all diameters for depths above 120 cm, width of trench in cm = diameter of pipe +
40 cm.
(c) Notwithstanding (a) and (b) the total width of trench shall not be less than 75 cm for
depths exceeding 90 cm.
The width of trench in the upper reaches shall be increased as described in sub-head
‘Earthwork’.

(ii) Laying (Fig. 19.11) : Where the pipes are laid on soft soil with maximum water table lying at invert
level of the pipe, the pipes shall be bedded in cement concrete with thickness and mix as specified,
projecting on each side of the pipe to the specified width of the trench (Fig. 19.11(i)). The pipes with
their crown level at 1.20 m depth and less from ground shall be covered with 15 cm thick. Concrete
above the crown of the pipe and sloped off to meet the outer edges of the concrete, to give a
minimum thickness of 15 cm all-around the pipe (Fig. 19.11 (iii)). Pipes laid at a depth greater than
1.20 m at crown and maximum water table level rising above the invert level of pipe, shall be
concreted at the sides up to the level of the centre of the pipe and sloped off from the edges to meet
the pipe tangentially (Fig. 19.11(ii)).
The pipe shall be carefully laid to the alignments, levels and gradients shown on the plans and sections.
Great care shall be taken to prevent sand etc. from entering the pipes. The pipes between two manholes
shall be laid truly in a straight line without vertical or horizontal undulation. The pipes shall be laid with
socket ends facing upstream. The body of the pipe shall for its entire length rest on an even bed of
concrete and places shall be excavated in the concrete to receive the socket of the pipe.
Where pipes are not bedded on concrete, the trench floor shall be left slightly high and carefully
bottomed up as pipe laying proceeds, so that the pipe barrels rest on firm and undisturbed ground.
If the excavation has been carried too low, the desired levels shall be made up with concrete 1:5:10
(1 cement: 5 fine sand: 10 graded stone aggregate 40 mm nominal size) for which no extra payment
shall be made.
If the floor of the trench consists of rock or very hard ground that cannot easily be excavated to
smooth surface the pipe shall be laid on a levelling course of concrete as desired.
When S.W. pipes are used for storm water drainage, no concreting will normally be necessary. The
cement mortar for jointing will be 1:3 (1 cement: 3 fine sand). Testing of joints will also not be done.
(iii) Jointing : Tarred gasket or hemp yarn soaked in thick cement slurry shall first be placed round the
spigot of each pipe and the spigot shall then be slipped home well into the socket of the pipe previously
laid. The pipe shall then be adjusted and fixed in the correct position and the gasket caulked tightly
home so as to fill not more than 1/4th of the total depth of the socket.
The remainder of the socket shall be filled with stiff mixture of cement mortar in the proportion of 1:1
(1 cement: 1 fine sand). When the socket is filled, a fillet shall be formed round the joint with a trowel
forming an angle of 45 degree with the barrel of the pipe.
After a day’s work any extraneous material shall be removed from the inside of the pipe. The newly
made joints shall be cured for at least seven days.
(iv) Testing of Joints : Stoneware pipes used for sewers shall be subjected to a test pressure of 2.5 m
head of water at the highest point of the section under test. Before commencing test, the pipeline
shall be filled with water and maintained full for 24 hours under head of 0.6 m of water. The test shall
be carried out by suitably plugging the lower end of the drain and the ends of the connection if any
and filling the system with water. A knuckle bend shall be temporarily jointed in at the top end and
a sufficient length of vertical pipe jointed to it so as to provide the required test head, or the top may
be plugged with a connection to a hose ending in a funnel which could be raised or lowered till the
required head is obtained and fixed suitable for observation. The tolerance of two liters per centimeter
of diameter per kilometer may be allowed during a period of 10 minutes.
If any leakage is visible, the defective part of the work shall be cut out and made good. A slight amount
of sweating which is uniform may be overlooked, but excessive sweating from a particular pipe or joint
shall be watched for and taken as indicating a defect to be made good.
Any joint found leaking or sweating, shall be rectified or embedded into 15 cm layer of cement
concrete (1:2:4) 30 cm in length and the section retested.

(v) Refilling : In cases where pipes are not bedded on concrete special care shall be taken in
refilling trenches to prevent the displacement and subsequent settlement at the surface
resulting in uneven street surfaces and dangers to foundations etc. The backfilling materials
shall be packed by hand under and around the pipe, and rammed with a shovel and light
tamper. This method of filling will be continued up to the top of pipe. The refilling shall rise
evenly on both sides of the pipe continued up to 60 cm above the top of pipe so as not to
disturb the pipe. No tamping should be done within 15 cm of the top of pipe.
(vi) Measurements : The lengths of pipes shall be measured in running metres nearest to a cm
as laid or fixed, from inside of one manhole to the inside of the other manhole. The length
shall be taken along the centre line of the pipes over all fittings such as bends, junctions,
etc. which shall not be measured separately.
Excavation, refilling, shoring and timbering in trenches, and cement concreting wherever
required shall be measured separately under relevant items of work.
(vii) Rate : The rate shall include the cost of materials and labour involved in all the operations
described above excluding the cost of concrete which shall be paid for separately.
19.2.1.3 Fixing S.W. Gully Trap (Fig. 19.2)

(i) Excavation : The excavation for gully traps shall be done true to dimensions and levels as
indicated on plans or as directed by the Engineer-in-Charge.
(ii) Fixing : The gully traps shall be fixed on cement concrete foundation 65 cm square and not
less than 10 cm thick. The mix for the concrete will be 1:5:10 (1 cement: 5 fine sand: 10
graded stone aggregate 40 mm nominal size). The jointing of gully outlet to the branch
drain shall be done similar to jointing of S.W. pipes described above.
(iii) Brick Masonry Chamber : After fixing and testing gully and branch drain, a brick masonry
chamber 300 x 300 mm (inside) in brick work of specified class in cement mortar 1:4 (1
cement: 4 fine sand) shall be built with a half brick thick brick work round the gully trap from
the top of the bed concrete up to ground level. The space between the chamber walls and
the trap shall be filled in with cement concrete 1:5:10 (1 cement: 5 fine sand: 10 graded
stone aggregate 40 mm nominal size). The upper portion of the chamber i.e. above the top
level of the trap shall be plas-tered inside with cement mortar 1:3 (1 cement: 3 coarse
sand), finished with a floating coat of neat cement. The corners and bottom of the chamber
shall be rounded off so as to slope towards the grating.
C.I. cover with frame 300 × 300 mm (inside) shall then be fixed on the top of the brick
masonry with cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate
20 mm nominal size) and rendered smooth. The finished top of cover shall be left about 4
cm above the adjoining ground level so as to exclude the surface water from entering the
gully trap.
(iv) Measurements : The work shall be enumerated. Excavation shall be measured separately
under relevant item of earth work.
(v) Rate : The rate shall include the cost of materials and labour involved in all the operations
described above, except earth work which shall be paid for separately.

19.2.2 Cement Concrete Pipes (with and without Reinforcement) (Light Duty, Non-Pressure)
The pipes shall be with or without reinforcement as required and shall be of class not lesser than
NP2. These shall conform to IS 458 and shall be capable of withstanding a test pressure of 0.07 MPa
(7 m head). The reinforced cement concrete pipes shall be manufactured by centrifugal (or spun)
process while un -reinforced cement concrete pipes by spun or pressure process. All pipes shall be
true to shape, straight, perfectly sound and free from cracks and flaws. The external and internal
surface of the pipes shall be smooth and hard. The pipes shall be free from defects resulting from
imperfect grading of the aggregate mixing or moulding.
Concrete used for the manufacture of un-reinforced and reinforced concrete pipes and collars
shall not be leaner than 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate). The maximum
size of aggregate should not exceed one third of the thickness of the pipe or 20 mm whichever is
smaller for pipes above 250 mm internal diameter. But for pipes of internal diameter 80 to 250 mm,
the maximum size of aggregate should be 10mm. The reinforcement in the reinforced concrete pipes
shall extend throughout the length of the pipe. The circumferential and longitudinal reinforcements
shall be adequate to withstand the specified hydrostatic pressure and further bending stresses due
to the weight of water when running full across a span equal to the length of pipe plus three times its
own weight.
The dimensional requirements of concrete pipes are given in Appendix I.
The minimum clear cover for reinforcement in pipes and collars shall be as given in Table 19.3.
TABLE 19.3
Sl. No. Precast concrete pipe/collar Minimum clear cover, mm
(i) Barrel wall thickness
(a) Upto and including 75 mm 8
(b) Over 75 mm 15
(ii) At spigot steps 5
(iii) At end of longitudinal 5
Note : An effective means shall be provided for maintaining the reinforcement in position and for
ensuring correct cover during manufacture of the unit. Spacers for this purpose shall be of rust proof
material or of steel protected against corrosion.
19.2.2.1 Laying and Jointing Cement Concrete Pipes and Specials

(i) Trenches: Trenches shall be as described in 18.4.4. Where the pipes are to be bedded
directly on soil, the bed shall be suitably rounded to fit the lower part of the pipe, the cost
for this operation being included in the rate for laying the pipe itself.
(ii) Loading, transporting and unloading of concrete pipes shall be done with care. Handling
shall be such as to avoid impact. Gradual unloading by inclined plane or by chain pulley
block is recommended. All pipe sections and connections shall be inspected carefully before
being laid. Broken or defective pipes or connections shall not be used. Pipes shall be
lowered into the trenches carefully. Mechanical appliances may be used. Pipes shall be
laid true to line and grade as specified. Laying of pipes shall proceed upgrade of a slope.
(iii) If the pipes have spigot and socket joints, the socket ends shall face upstream. In the case
of pipes with joints to be made with loose collars, the collars shall be slipped on before the
next pipe is laid. Adequate and proper expansion joints shall be provided where directed.

(iv) In case where foundation conditions are unusual such as in the proximity of trees or holes,
under existing or proposed tracks manholes etc. the pipe shall be encased all-around in 15
cm thick cement concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone aggregate 40
mm nominal size) or compacted sand or gravel.
(v) In cases where the natural foundation is inadequate the pipes shall be laid either in concrete
cradle supported on proper foundations or on any other suitably designed structure. If a
concrete cradle bedding is used the depth of concrete below the bottom of the pipe shall
be at least 1/4th of the internal dia of the pipe subject to the min. of 10 cm and a maximum
of 30 cm. The concrete shall extend up the sides of the pipe at least to a distance of 1/4th
of the outside diameter of pipes 300 mm and over in dia. The pipe shall be laid in this
concrete bedding before the concrete has set. Pipes laid in trenches in earth shall be
bedded evenly and firmly and as far up the haunches of the pipe as to safely transmit the
load expected from the backfill through the pipe to the bed. This shall be done either by
excavating the bottom of the trench to fit the curve of the pipe or by compacting the earth
under around the curve of the pipe to form an even bed. Necessary provision shall be
made for joints wherever required.
(vi) When the pipe is laid in a trench in rock hard clay, shale or other hard material the space
below the pipe shall be excavated and replaced with an equalising bed of concrete, sand
or compacted earth. In no place shall pipe be laid directly on such hard material.
(vii) The method of bedding and laying the pipes under different conditions are illustrated in
Fig. 19.9.
(viii) When the pipes are laid completely above the ground the foundations shall be made even
and sufficiently compacted to support the pipe line without any material settlement.
Alternatively the pipe line shall be supported on rigid foundations at intervals. Suitable
arrangements shall be made to retain the pipe line in the proper alignment, such as by
shaping the top of the supports to fit the lower part of the pipe. The distance between the
supports shall in no case exceed the length of the pipe. The pipe shall be supported as far
as possible close to the joints. In no case shall the joints come in the centre of the span.
Care shall be taken to see that super imposed loads greater than the total load equivalent
to the weight of the pipe when running full shall not be permitted.
Suitably designed anchor blocks at change of direction and grades for pressure lines shall
be provided where required.
(ix) Jointing: Joints are generally of rigid type. Where specified flexible type joints may also be
provided.
(a) Rigid Spigot and Socket Joint (Fig. 19.10): The spigot of each pipe shall be slipped
home well into the socket of the pipe previously laid and adjusted in the correct
position. The opening of the joint shall be filled with stiff mixture of cement mortar in
the proportion of 1:2 (1 cement: 2 fine sand) which shall be rammed with caulking
tool. After a day’s work any extraneous material shall be removed from the inside of
the pipe and the newly made joint shall be cured.
(b) Rigid Collar Joint (Fig. 19.10): The two adjoining pipes shall be butted against each
other and adjusted in correct position. The collar shall then be slipped over the joint,
covering equally both the pipes. The annular space shall be filled with stiff mixture of
cement mortar 1:2 (1 cement: 2 fine sand) which shall be rammed with caulking fool.
After a day’s work any extraneous materials shall be removed from the inside of the
pipe and the newly made joint shall be cured.

(c) Semi Flexible Spigot and Socket Joint (Fig. 19.10): The joint is composed of specially
shaped spigot and socket ends on the concrete pipes. A rubber ring shall be placed
on the spigot which shall be forced into the socket of the pipe previously laid. This
compresses the rubber ring as it rolls into the annular space formed between the two
surfaces of the spigot and the socket, stiff mixture of cement mortar 1:2 (1 cement: 2
fine sand) shall then be filled into the remaining annular space and rammed with a
caulking tool. After day’s work any extraneous materials shall be removed from the
inside of the pipe and the newly made joint shall be cured.
(d) Semi Flexible Collar Joint: This is made up of a loose collar which covers two specially
shaped pipe ends as shown in the Fig. 19.10. Each end shall be fitted with a rubber
ring which when compressed between the spigot and the collar, seal the joint. Stiff
mixture of cement mortar 1:2 (1 cement: 2 fine sand), shall then be filled into the
remaining annular space and rammed with a caulking tool. After day’s work, any
extraneous material shall be removed from the inside of the pipe and the newly made
joint shall be cured.
(e) Internal Flush Joint (Fig. 19.10): This joint is generally used for culvert pipe of 60 cm
dia and over. The ends of the pipe are specially shaped to form a self centering joint
with an internal jointing space 1.3 cm wide the finished joint is flush with both inside
and outside with the pipe wall as shown in Fig. 19.10. The jointing space is filled with
cement mortar 1:2 (1 cement: 2 fine sand) mixed sufficiently dry to remain in position
when forced with a trowel or rammer. After day’s work, any extraneous material shall
be removed from the inside of the pipe and the newly made joint shall be cured.
(f) External Flush Joint : This joint is suitable for pipes which are too small for jointing
from inside. This joint is composed of specially shaped pipe ends as shown in Fig.
19.10. Each end shall be butted against each other and adjusted in correct position.
The jointing space shall then be filled with cement mortar 1:2 (1 cement: 2 fine sand)
sufficiently dry and finished off flush. Great care shall be taken to ensure that the
projecting ends are not damaged as no repairs can be readily affected from inside
the pipe.
(x) In all pressure pipe lines the recess at the end of the pipe line shall be filled with jute
braiding dipped in hot bitumen or other suitable approved compound. Pipes shall be so
jointed that the bitumen ring of one pipe shall set into the recess of the next pipe. The ring
shall be thoroughly compressed by jacking or by any other suitable method.
The number of pipes that shall be jacked together at a time shall depend on the diameter
of the pipes and the bearing capacity of the soil, for small pipes up to 25 cm diameter, six
pipes can be jacked together at a time.
The quantity of jute and bitumen in the ring shall be just sufficient to fill the recess in the
pipe when pressed hard by jacking or by any other suitable method. Before and during
jacking care shall be taken to see that there is no offset at the joint.
(xi) Testing: For pressure pipes, the completed pipeline shall be tested for pressure (Known as
site test pressure) which shall not be less than the maximum pipeline operating pressure
plus the calculated surge pressure, but in no case shall it exceed the hydrostatic test
pressure. For non-pressure pipes the joints shall be tested as per procedure laid down
under Para 19.2.1.2 (iv).

(xii) Refilling of Trenches: The specification described in 19.2.1.2 (v) shall apply. In case where
pipes are not bedded on concrete special care shall be taken in refilling, trenches to prevent
the displacement and subsequent settlement at the surface resulting in uneven street
surfaces and dangers to foundations etc. The backfilling materials shall be packed by
hand under and around the pipe and rammed with a shovel and light tamper. This method
of filling will be continued up to the top of pipe. The refilling shall rise evenly on both sides
of the pipe and continued up to 60 cm above the top of pipe so as not to disturb the pipe.
No tamping shall be done within 15 cm of the top of pipe. The tamping shall become
progressively heavier as the depth of the backfill increases.
(xiii) Measurements : The lengths of pipes shall be measured in running metres nearest to a cm
as laid or fixed, from inside of one manhole to the inside of the other manhole. The length
shall be taken along the centre line of the pipes over all fittings such as bends, collars,
junctions, etc. which shall not be measured separately.
Excavation, refilling, shoring and timbering in trenches, and cement concreting wherever
required shall be measured separately under relevant items of work.
(xiv) Rate: The rate shall include the cost of materials and labour involved in all the operations
described above.
19.2.3 Cast Iron (Centrifugally Cast) Pipes and Specials

Cast iron (centrifugally cast) pipes and specials shall conform to the specifications described
in 18.3.10.
19.2.4 Road Gully Grating (Fig. 19.13)

19.2.4.1 Horizontal Gully Grating: The casting of the grating and frames shall be the same as that
of manhole covers described in 19.2.2.1. The gully grating cover shall be hinged to the frame to
facilitate its opening for cleaning and repairs. A typical grating is shown in Fig. 19.13 & 19.14. The
weight of grating shown in Figure shall be minimum 75 Kg. In case of R.C.C. horizontal gully grating
it shall be in cement concrete 1:1:2 (1 cement: 1 coarse sand: 2 graded stone aggregate 20 mm
nominal size) as shown in Fig. 19.13.
19.2.4.2 Vertical Gully Grating: The chamber shall be of brick masonry, 12 mm dia, round bar shall
be fixed in cement concrete block at the bottom. The bars at the top shall be welded or riveted to
M.S. flat 40×6 mm as shown in Fig. 19.14.
19.2.4.3 Horizontal and Vertical Gully Grating: The details of typical road gully chamber of brick
masonry with horizontal and vertical grating shall be as given in Fig. 19.14.
19.3 MANHOLE COVERS & FRAMES

19.3.1 Manhole Covers
The covers and frames shall conform to IS 1726 for cast Iron and IS 12592 for pre-cast concrete
covers and shall be of the following grades and types.
Grades Grade Type/shape of cover
Designation
Light Duty LD - 2.5 Rectangular, Square, Circular
Rectangular, Circular and Square (for pre-cast concrete
Medium Duty MD - 10 manhole covers)
Heavy Duty HD - 20 Circular-Square, Rectangular, (Scrapper Manhole)
Extra Heavy Duty EHD - 35 Circular, Square, Rectangular, (Scrapper Manhole)

19.3.1.1 Cast Iron Manhole Covers and Frames
(i) Manhole covers and frame shall be manufactured from appropriate grade of grey cast iron
not inferior than FG150 grade of IS 210.
(ii) They shall be cleanly cast and shall be free from air and sand holes, cold shuts and warping.
(iii) Covers shall have on its operative top a raised chequered design to provide for an adequate
no-slip grip. The rise of chequers shall be not less than 4mm.
(iv) Key holes, keys and lifting devices shall be provided in the manhole covered to facilitate
their placement in the frames and their operative maintenance.
(v) Manhole covers and frames shall be coated with materials having base with a black bituminous
composition. The coating shall be smooth and tenacious. It shall not flow when exposed to
temperature of 63°C and shall not be so brittle as to chip off at temperature of 0°C.
(vi) Size and shape and performance requirement of manhole covers and frames shall conform
to IS 1726.
(vii) Each manhole covers and frame shall have cast on them the following information:
(a) Manufacturer’s name or trade-mark
(b) Grade designation
(c) Date of manufacturer
(d) The words SWD or ’Sewer’ to denote ‘storm water drain’ or ‘sewer’ respectively
(e) Identification marks as required by Engineer-in-Charge.
(viii) The cover shall be gas tight and water tight.
(ix) The sizes of covers specified shall be taken as the clear internal dimensions of the frame.
(x) The approximate weight of the various type of manhole covers and frames shall be as per
IS 1726.
(xi) The cover shall be capable of easy opening and closing and it shall be fitted in the frame in
workmanship like manner.
19.3.2 Pre-Cast Concrete Manhole Covers & Frames

Pre-cast reinforced cement concrete manhole covers intended for use in sewerage and water
works shall generally conform to IS 12592.
19.3.2.1 Materials
Cement: Cement used for the manufacture of pre-cast concrete manhole covers shall be 43 grade
Portland cement conforming to IS-8112.
Aggregates: The aggregates used shall be clean and free from deleterious matter and shall conform
to the requirements of IS -383. The aggregates shall be well graded and the nominal maximum size
of coarse aggregate shall not exceed 20 mm.
Concrete: The mix proportions of concrete shall be determined by the manufacturer and shall be
such as will produce a dense concrete without voids, honey combing etc. The minimum cement
content in the concrete shall be 410 kg/m3 with a maximum water cement ratio of 0.45. Concrete
weaker than grade M-30 (design mix) shall not be used. Compaction of concrete shall be done by
machine vibration.

Reinforcement
(a) The reinforcement steel shall conform to IS 1786. Reinforcement shall be clean and free from loose
mill scale, loose rust, and mud, oil, grease or any other coating which may reduce or destroy the
bond between the concrete and steel. A light film of rust may not be regarded as harmful but steel
shall not be visibly pitted by rust.
(b) Fibers Steel: The diameter/equivalent diameter of steel fibers where used, shall not be greater than
0.75 mm. The aspect ratio shall be in the range of 50 to 80. The minimum volume of fibers shall be
0.5 percent of the volume of concrete.
The reinforced concrete manhole cover and frame shall be designed in accordance with the provisions of
IS 456. Clear cover to reinforcement shall not be less than 15 mm.
19.3.2.2 Shapes and Dimensions: Shape, dimensions and tolerance of pre-cast concrete manhole covers
and frames shall conform to IS 12592. Outside dimension of cover at top shall match with corresponding
frame so that the maximum clearance at top between the frame and the cover all round the periphery is not
more than 5 mm and the top surface of the frame and covers, is in level within a tolerance of +5 mm.
For facility of removing the cover from the frame, suitable taper matching with taper given for the frame shall
be provided to the periphery of the cover.
19. 3.2.3 Lifting Device: The minimum diameter of mild steel rod used as lifting device shall be 12 mm for
light and medium duty covers and 16 mm for heavy and extra heavy duty covers. The lifting device shall be
protected from corrosion by hot galvanising or epoxy coating or any other suitable treatment.
19. 3.2.4 Finishing & Coating: To prevent any possible damage from corrosion of steel the underside of the
covers shall be treated with anticorrosive paint. The top surface of the covers shall be given a chequered finish.
In order to protect the edges of the covers from possible damage at the time of lifting and handling it is
necessary that the manhole covers shall be cast with a protective mild steel sheet of minimum 2.5 mm
thickness around the periphery of the covers. Exposed surface of mild steel sheet shall be given suitable
treatment with anticorrosive paint or coating. To prevent the top outer edge of frame from possible damages,
it shall be protected by 25 mm X 3 mm mild steel flat as part of the frame.
19.3.2.5 Physical Requirements

(a) General: All units shall be sound and free from cracks and other defects which interface with the
proper placing of the unit or impair the strength or performance of the units. Minor chipping at the
edge/surface resulting from the customary methods of handling during delivery shall not be deemed
for rejecting.
(b) Load Test: The breaking load of individual units when tested in accordance with the method described
in IS 12592 shall be not less than the values specified in Table 19.4.
TABLE 19.4
Grade of Cover Type Load in Tonnes Diameter of Blocks in mm
EHD - 35 Circular, Square or Rectangular 35 300
HD - 20 Circular, Square or Rectangular 20 300
MD - 10 Circular or Rectangular 10 300
LD - 2.5 Rectangular, Square or Circular 2.5 300
19.3.2.6 Fixing: The frames of manhole shall be firmly embedded to correct alignment and level in
RCC slab or plain concrete as the case may be on the top of masonry which shall be paid as extra
unless specified otherwise.
19.3.2.7 Measurements: The manhole covers shall be enumerated under relevant items.

19.3.2.8 Rates: The rate shall include the cost of materials and labour involved in all the operation
described above except fixing of frames and covers which shall be paid as extra unless specified
otherwise in the item.
19.3.2.9 Foot Rests: Foot rests shall be of 20 mm M.S. square or round bars as specified.
19.4 MANHOLES (FIG. 19.3 to 19.8)

At every change of alignment, gradient or diameter of a drain, there shall be a manhole or inspection
chamber. Bends and junctions in the drains shall be grouped together in manhole as far as possible.
The maximum distance between manholes shall be 30 m.
Manholes of different types and sizes as specified shall be constructed in the sewer line at such
places and to such levels and dimensions as shown in the drawings or as directed by the Engineer -
in-Charge. The size specified shall indicate the inside dimensions between brick faces of the manholes.
Where the diameter of the drain is increased, the crown of the pipe shall be fixed at the same
level and necessary slope given in the invert of the manhole chamber. In exceptional cases and
where unavoidable, the crown of the branch sewer may be fixed at lower level but in such cases the
peak flow level of the two sewers shall be kept the same.
Sewers of unequal sectional area shall not be jointed at the same invert in a manhole. The invert
of the smaller sewer at its junction with main shall be at least 2/3 the diameter of the main above the
invert of the main. The branch sewers shall deliver sewage in the manhole in the direction of main
flow and the junction must be made with care so that flow in main is not impeded.
No drain from house fittings, e.g. gully trap or soil pipe, etc. to manhole shall normally exceed a
length of 6 m unless it is unavoidable.
Manholes 90 × 80 cm are generally constructed within compound for house drainage only and
near the buildings for house drainage. Manholes 1.2 m × 90 cm are generally constructed for main
drainage work for depths less than 1.5 m.
Manhole 1.4 m × 90 cm is of the arched type and is generally constructed for main drainage
works where depth is 1.50 m or more. The width of manholes shall be increased more than 90 cm on
bends or junctions or pipes with diameter greater than 450 mm and that the benching width on either
side of the channel is minimum 20 cm.
Manholes 1.4 m internal diameter are generally constructed for main drainage works where depth
is 2.45 m or more as an alternative to manholes of arch type. The diameter shall be increased
suitably, for pipes with diameter greater than 450 mm in the same manner as in the case of rectangular
manholes.
Before deciding size of manholes, Local Municipal Bye Laws shall be consulted. As a general
guide some typical type designs of manholes followed in Delhi have been shown in Fig. 19.4 to 19.7.
When manholes are constructed on foot path, these shall be provided with cover of medium duty
casting and when built within the width of the road under vehicular traffic, these shall be provided
with cover of heavy duty casting.
19.4.1 Excavation
The excavation for manhole shall be true to dimensions and levels shown on the plans or as
directed by the Engineer-in-Charge.

19.4.2 Bed Concrete
The manhole shall be built on a bed of cement concrete 1:4:8 (1 cement: 4 coarse sand: 8 graded stone
aggregate 40 mm nominal size) unless required by local authorities. The thickness of the bed concrete shall
be 20 cm for manholes up to 4.25 m depth and 30 cm for depths beyond 4.25 m unless otherwise specified or
directed by the Engineer-in-Charge. In bad ground, special foundations as suitable shall be provided.
19.4.3 Brick Work

The brick work shall be with class 75 bricks in cement mortar 1:4 (1 cement: 4 coarse sand). The external
joints of the brick masonry shall be finished smooth, and the joints of the pipes with the masonry shall be made
perfectly leak proof. For arched type and circular manholes, brick masonry in arches and arching over the pipes
shall be in cement mortar 1.3 (1 cement: 3 fine sand). In the case of manholes of circular type the excess shaft
shall be corbelled inwardly on three sides at the top to reduce its size to the cover frame to be fitted.
The walls shall be built of one brick thickness for depths up to 4.25 m. Below a depth of 4.25 m in ordinary
subsoil the wall thickness shall be increased to one and half brick and at 9.75 m below ground two brick thick
walls shall be built.
19.4.4 Plaster and Pointing

The walls of the manholes shall be plastered inside with 12 mm thick cement plaster 1:3 (1 cement: 3
coarse sand) finished smooth. In the case of arched type manhole the walls of the manhole shall be plastered
inside all-around only up to the crown level, and flush pointed for the shaft with cement mortar 1:2 (1 cement:
2 fine sand). Where the saturated soil is met with, also the external surface of the walls of the manhole shall
be plastered with 12 mm thick cement plaster 1:3 (1 cement: 3 coarse sand) finished smooth up to 30 cm
above the highest sub-soil water level with the approval of the Engineer-in-Charge. The plaster shall further be
water proofed with addition of approved water proofing compound in a quantity as per manufacturer’s
specifications. In case Local Authorities/Bye Laws specify richer specifications, the same shall be adopted.
For earth work excavation, bed concrete brick work, plaster and pointing, R.C.C. work and refilling of
earth, respective specifications shall be followed.
19.4.5 Benching
The channels and benching shall be done in cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded
stone aggregate 20 mm nominal size) and rendered smooth with neat cement. The depth of channels and
benching shall be as given in Table 19.5.
19.4.6 Foot Rests (Fig. 19.8)

All manholes deeper than 0.8 m shall be provided with M.S. foot rests. These shall be embedded 20 cm deep
in 20 x 20 x 10 cm blocks of cement concrete 1:3:6 (1 cement: 3 coarse sand 6 graded stone aggregate 20 mm
nominal size). The concrete block with M.S. foot rest placed in its centre shall be cast in situ along with the
masonry and surface finished with 12 mm thick cement plaster 1:3 (1 cement: 3 coarse sand) finished smooth.
TABLE 19.5
Sizes of drain Top of channel at the centre above Depth of benching at side walls above
(mm) bed concrete bed concrete
(cm) (cm)
100 15 20
150 20 30
200 25 35
250 30 40
300 35 45
350 40 50
400 45 55
450 50 60

Foot rests which shall be of 20 × 20 Sq. M.S. bars as shown in Fig. 19.8 shall be fixed 40 cm apart
vertically and staggered laterally and shall project 10 cm beyond the surface of the wall. The top foot
rest shall be 45 cm below the manhole cover.
Foot rests shall be painted with coal tar, the portion embedded in the cement concrete block
being painted with thick cement slurry before fixing.
19.4.7 Manhole Covers and Frames

The frame of manhole shall be firmly embedded to correct alignment and levels in R.C.C. slab or
plain concrete as the case may be on the top of the masonry. After completion of the work, manhole
covers shall be sealed by means of thick grease.
19.4.8 Measurements
Manholes shall be enumerated under relevant items. The depth of the manhole shall be reckoned
from the top level of C.I. cover to the invert level of channel. The depth shall be measured correct to
a cm. The extra depth shall be measured and paid as extra over the specified depth.
19.4.9 Rate
above but excludes the cost of (i) excavation, (ii) M.S. foot rests and (iii) 12 mm thick cement plaster
with water proofing material applied at the external surface of the manhole if required. These items
shall be paid for separately under relevant items of work.
Payment for extra depths of manholes shall be made separately under relevant items of work.
19.5 DROP CONNECTION (FIG. 19.8)

19. 5.0 In cases where branch pipe sewer enters the manhole of main pipe sewer at a higher level
than the main sewer, a drop connection shall be provided. The work shall be carried out as per Fig.
19.8. S.C.I. pipes and special conforming to IS 1729 shall be of the same size as that of the branch
pipe sewer.
For 150 and 250 mm main line, if the difference in level between the water line (peak flow level)
and the invert level of the branch line is less than 60 cm, a drop connection may be provided with in
the manhole by giving suitable ramp. If the difference in level is more than 60 cm, the drop shall be
provided externally.
The main lines up to 350 mm dia, are designed for half depth of flow, from 350 mm to 900 mm for
2/3 depth of flow and beyond 900 mm for 3/4 depth of flow.
19.5.1 Excavation
The excavation shall be done for the drop connection at the place where the branch line meets
the manhole. The excavation shall be carried up to the bed concrete of the manhole and to the full
width of the branch line.
19.5.2 Laying
At the end of branch sewer line S.C.I. cross shall be fixed to the line which shall be extended
through the wall of the manhole by a horizontal piece of S.C.I. pipe to form an inspection or cleaning
eye. The open end shall be provided with chain and lid. The S.C.I. drop pipe shall be connected to
the cross at the top and to the S.C.I. bend at the bottom. The bend shall be extended through the
wall of the manhole by a piece of C.I. pipe which shall discharge into the channel. Necessary
channel shall be made with cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone
aggregate 20 mm nominal size) and finished smooth to connect the main channel. The joint between

S.C.I. pipe and fittings shall be lead caulked as described in 18.5.3. The j oint between S.C.I. cross and
S.W. branch line shall be made with cement mortar 1:1 (1 cement: 1 fine sand). The exposed portion of the
drop connection shall be encased all-around with minimum 15 cm thick concrete 1:5:10 (1 cement: 5 fine
sand: 10 graded stone aggregate 40 mm nominal size) and cured. For encasing the concrete around the
drop connection, the necessary centering and shuttering shall be provided. The holes made in the walls of
the manhole shall be made good with brick work in cement mortar 1:4 (1 cement: 4 coarse sand) and
plastered with cement mortar 1:3 (1 cement: 3 coarse sand) on the inside of the manhole wall. The excavated
earth shall be back filled in the trench in level with the original ground level.
19.5.3 Measurements
Drop connection shall be enumerated. The depths beyond 60 cm shall be measured in running metres
correct to a cm under relevant items.
19.5.4 Rate
The rate shall include the cost of labour and materials involved in all the operations described above but
excluding the cost of excavations and refilling.
19.6 OPEN SURFACE DRAIN (FIG. 19.12)

The open drains shall be of the size, as specified in the item and laid to such gradients and in such
locations as may be shown in the relevant drawing or as directed by the Engineer-in-Charge.
The size of the drain as specified shall be the width of the drain at the top, measured between the masonry
walls. The drain shall be given, as far as possible, uniform slope from the starting point to the discharge point.
The average depths of the various sizes of drains shall be as follows:—

Drain size Depth
10 cm 20 cm
15 cm 20 cm
25 cm 30 cm
19.6.1 Measurements
The drains shall be measured in running metres, correct to a cm.
19.6.2 Rate
The rate shall include the cost of labour and materials required for all the operations described above,
suitable deduction or extra payment, per cm basis shall be made in case there is a variation in average
depths from those stated above.
19.7 ROAD GULLY CHAMBER WITH GRATING

19.7.1 Road Gully Chamber with Horizontal Grating (Fig. 19.14)
The chamber shall be of brick masonry of specified class and shall have a C.I. grating with frame fixed in 15 cm
thick cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone aggregate 20 mm nominal size) at the top.
The size of the chamber shall be taken as the clear internal dimensions of the C.I. frame. The chamber shall have
a connection pipe, the length of which in metre between the road gully chamber and the manhole of the drain shall
not be less than one by forty (1/40) times the nominal diameter of pipe in mm (i.e. for 150 mm connection pipe,
length shall not be less than 3.7 m and for 250 mm connection pipe length shall not be less than 6.25 m). The
chamber shall be built at the location fixed by the Engineer-in-Charge. Generally the spacing of the chambers shall
be 18 to 36 m depending upon the grading of the road channel and the area of the drainage. R.C.C. gully grating
shall be fixed in cement mortar 1:2 (1 cement: 2 coarse sand) as shown in Fig. 19.13.
19.7.2 Road Gully Chamber with Vertical Grating (Fig. 19.14)

The chamber shall be of brick masonry 12 mm dia round bar shall be fixed in cement concrete block at the
bottom. The bars at the top shall be welded or riveted to M.S. flat 40 × 6 mm as shown in Fig. 19.14. The
specifications shall be same as described in 19.7.1.

19.7.3 Road Gully Chamber with Horizontal and Vertical Grating
The details of typical road gully chamber of brick masonry shall be same as shown in Fig. 19.14.
19.7.4 Measurements
Road gully chambers shall be enumerated.
19.7.5 Rate
above except the cost of excavation and connection pipes.
19.8 BRICK MASONRY GULLY TRAP (FIG. 19.2)

The internal size of the trap shall be 80 × 40 × 46 cm. The height shall be measured from the top
of the floor to the top of the cover. 40 mm thick stone baffles shall be fixed 50 mm deep in masonry
with cement mortar 1:4 (1 cement: 4 fine sand), as shown in the Fig. 19.2. The connection of open
surface, drain with a soak pit shall be invariably through a grease trap.
19.8.1 Measurements
Grease traps shall be enumerated.
19.8.2 Rate
The rate shall include the cost of labour and materials required for all the operations described
above.
19.9 SEPTIC TANK (FIG. 19.15 & 19.16)

In unsewered area, every house shall have arrangements for its sewage being treated in septic
tank, effluent from which should be given secondary treatment either in a biological filter or on the
land, or in a sub-surface disposal system.
Surface and sub -soil water should be excluded from finding way into the septic tank. Waste water
may be passed into the septic tank provided the tank and the means for effluent disposal are designed
to cope up with this extra liquid. Depending on the location of the water table and the nature of the
strata, the type of disposal for the effluent from the septic tank shall be decided.
19.9.1 Dimensions
Septic tanks shall have minimum width of 75 cm, minimum depth of one metre below water level
and a minimum liquid capacity of the one cubic metre. Length of tanks shall be 2 to 4 times the width.
Suitable sizes of septic tanks for use of 5, 10, 15, 20 and 50 persons based on certain assumptions
are given in Appendix II.
19.9.2 Cover and Frame

Every septic tank shall be provided with C.I. cover of adequate strength. The cover and frames
shall be 500 mm dia. (M.D.) minimum or 610 mm × 455 mm (LD). The specification for frames and
cover given in 19.3.1 shall apply.
19.9.3 Ventilating Pipe

Every septic tank shall be provided with C.I. ventilating pipe of at least 50 mm diameter. The top of
the pipe shall be provided with a suitable cage of mosquito proof wire mesh.
The ventilating pipe shall extend to a height which would cause no smell nuisance to any building
in the area. Generally the ventilating pipe may extend to a height of about 2 m, when the septic tank
is at least 15 m away from the nearest building and to a height of 2 m. above the top of the building
when it is located closer than 15 metres. The ventilating pipe may also be connected to the normal
soil ventilating system of the building where so desired.

19.9.4 Disposal of Sludge
The sludge from septic tanks may be delivered into covered pit or into a suitable vehicle for
removal from the site. Spreading of sludge on the ground in the vicinity shall not be allowed.
19.9.5 Testing
Before the tank is commissioned for use, it shall be tested for water-tightness by filling it with
water and allowing it to stand for 24 hours. It shall then be topped up, if necessary, and allowed to
stand for a further period of 24 hours during which time the fall in the level of the water shall not be
more than 1.5 cm.
19.9.6 Commissioning of Septic Tank

The tank shall be filled with water to its outlet level before the sewage is let into the tank. It shall,
preferably, be seeded with small quantities of well digested sludge obtained from septic tanks or
sludge digestion tanks. In the absence of digested sludge a small quantity of decaying organic
matter, such as digested cow-dung, may be introduced.
19.9.7 Sub-Surface Absorption System

The effluent from septic tank shall be disposed of by soak pit or dispersion trench depending on
the position of the sub-soil water level, soil and sub-soil conditions and the size of the installation.
19.9.8 Measurements
Septic tank shall be enumerated.
19.9.9 Rate
The rate shall include the cost of materials and labour involved in all the operation, except Sub-
Surface absorption system which shall be paid for separately.
19.10 SOAK PITS 2.5 M DIA × 3 M DEEP (FIG. 19.17)

The earth excavation shall be carried out to the exact dimensions as shown in the figure. In the
soak pit shall be constructed a honey-comb dry brick shaft 45 x 45 cm and 292.5 cm high. Round the
shaft and within the radius of 60 cm shall be placed well burnt brick bats. Brick ballast of size from 50
to 80 mm nominal size shall be packed round the brick bats up to the radius of 90 cm. The remaining
portion shall be filled with brick ballast of 40 mm nominal size. The construction of shaft and filling of
the bats and the ballast shall progress simultaneously.
19.10.2 Cover and Drain

Over the filling shall be placed single matting which shall be covered with minimum layer of 7.5 cm
earth. The shaft shall be covered with 7.5 cm thick stone or R.C.C. slab 10 cm wide and 10 cm deep
brick edging with bricks of class designation 75 shall be provided round the pit. The connection of
the open surface drain to the soak pit shall be made by means of 100 mm diameter S.W. pipe with
open joints.
Soak pit shall be enumerated.
19.10.4 Rate
Rate shall include the cost of labour and material involved in all the operations described above.

19.11 SOAK PIT 1.2 × 1.2 × 1.2 M
The earth excavation shall conform to the general specifications for earth work. After the excavation
is complete the soak pit shall be filled with brick bats. The brick bats shall be from properly burnt
bricks. 10 cm wide and 10 cm deep brick edging with bricks of class designation 75 shall be provided
round the soak pit.
Soak pits shall be enumerated.
19.11.3 Rate
Rate shall include the cost of labour and materials involved in all the operations.
19.12 DISPERSION TRENCH (FIG. 19.18)

It shall be provided when the sub-soil water level is within 180 cm from the ground level. Dispersion
trenches are not recommended in areas where fibrous roots of trees or vegetation are likely to
penetrate the system and cause blockages.
Dispersion trenches shall be 50 to 100 cm deep and 30 to 100 cm wide, excavated to a slight
gradient and shall be provided with 15 to 25 cm of washed gravel or crushed stones. Open jointed
pipes placed inside the trench shall be made of unglazed earthenware clay or concrete and shall
have minimum internal diameter of 75 to 100 mm. Each dispersion trench should not be longer than
30 m and trenches should not be placed closer than 1.8 m.
The covering for the pipes on the top shall be with coarse aggregate of uniform size to a depth of
approximately 15 cm. The aggregate above this level may be graded with aggregate 12 to 15 mm to
prevent ingress of top soil while the free flow of water is no way retarded. The trench may be covered
with about 30 cm of ordinary soil to form a mound and turned over. The finished top surface may be
kept at least 15 cm above ground level to prevent direct flooding of the trench during rains.
The length of dispersion trench shall be measured in running metres nearest to a cm.
19.12.3 Rate
19.13 DESLUDGING OF SEPTIC TANKS

Septic tanks shall be desludged periodically, the intervals of desludging, depending upon the
design of the septic tanks and the capacity in relation to its users. Desludging may be done when the
sludge level reaches a predetermined level. A portion of the sludge may be left in the tank to seed
the fresh deposits.
Desludging shall preferably be carried out by hydrostatic head or by using a portable pump.
Manual handling of sludge shall be discouraged.
19.14 DISMANTLING OF OLD S.W. PIPES

The specification specified in clause 15.3.16 shall be applicable.
19.15 6 MM THICK PLASTIC ENCAPSULATED M.S. FOOT REST

19.15.1 All manholes deeper than 0.8 m shall be provided with foot rests. These shall be embedded
13.8 cm deep in 30x20x15 cm blocks of cement concrete 1:3:6 (1 cement: 3 coarse sand 6 graded
stone aggregate 20 mm nominal size). The concrete block with foot rest placed in its centre shall be
cast in situ along with the masonry and surface finished with 12 mm thick cement plaster 1:3 (1
cement: 3 coarse sand) finished smooth.

Foot rests which shall be of 6 mm thick plastic encapsulated as per IS:10910 on 12 mm dia steel bar
as shown in Fig. 19.19 shall be fixed 40 cm apart vertically and staggered laterally and shall project
12.5 cm beyond the surface of the wall. The top foot rest shall be 45 cm below the manhole cover.
1. Minimum 6 mm thick Polypropylene and its copolymers conforming to IS-10910 shall be
moulded around a 12 mm dia steel bar.
2. Overall minimum length shall be of 263 mm and width as 165 mm (U shape 691 mm) with
minimum 112 mm space between protruded legs having a 2 mm tread on top surface by
ribbing or chequering besides necessary and adequate anchoring projections on tail length
of 138 mm as per standard drawing and suitable to with stand the bend test and chemical
resistance test as per specifications and having manufacture’s permanent identification
mark to be visible even after fixing.
The foot-rest shall be enumerated under the relevant item.
19.15.3 Rate
The rate shall include the cost of labour and material involved in all the operations described above.
19.16 REPLACEMENT OF M.S. FOOT RESTS IN MANHOLES

The specification specified in clause 19.4.6 shall be applicable.
19.17 RAISING OF MANHOLE COVER AND FRAME SLAB

19.17.1 General
Removal of RCC Cover and frame

Shall be removed carefully and stacked properly as per direction of Engineer-in-charge.
Dismantling of RCC Slab

Dismantling of RCC slab shall conform to the specifications described in para 15.3.11.
Brick Works
Brick work shall conform to the specifications described in para 19.4.3
Plaster and pointing

Plaster and pointing shall conform to the specifications described in para 19.4.4.
Frame Work (centering & shuttering)

Frame Work (centering & shuttering) shall conform to the specifications described in para 5.2
RCC Work
RCC Work shall conform to the specifications described in para 5.4
Placing of Covers and Frames
Placing of Covers and Frames shall conform to the specifications described in para 19.4.7.
Raising of Manhole shall be enumerated under relevant items.
19.17.3 Rate
The rate shall include the cost of materials and labour involved in all the operations described above
but excludes the cost of (i) Reinforcement and (ii) The raising depth of the manhole to be paid separately.

19.18 INSPECTION CHAMBER (FIG.19.20 to 19.22 )
19.18.1 At every change of alignment, gradient or diameter of drain, their shall be a inspection
chamber. Bends and junctions in the drain shall be group together in inspection chamber as far as
possible. The maximum distance between chambers shall be 30m.
Inspection chambers of different types and sizes as specified shall be constructed in the drainage
line at such places and to such levels and dimensions as shown in the drawings or as directed by the
Engineer-in Charge. The size specified shall indicate the inside dimensions between brick faces of
the inspection chamber.
Where the diameter of the drain is increased, the crown of the pipe shall be fixed at the same
level and necessary slope given in the invert of the inspection chamber. In exceptional cases and
where unavoidable, the crown of the branch drainage may be fixed at lower level but in such cases
the peak flow level of the two drainage shall be kept the same.
Drainage of unequal sectional area shall not be jointed at the same invert in a inspection chamber.
The invert of the smaller drainage at its junction with main shall be at least 2/3 the diameter of the
main above the invert of the main. The branch drainage shall deliver drainage in the inspection
chamber in the direction of main flow and the junction must be made with care so that flow in main is
not impeded.
Inspection chamber of 455 × 610 mm and 45 cm deep for single pipe line, 500 × 700 mm and
45 cm deep for one or two inlets and 600 × 850 mm and 45 cm deep for three or more inlets are
generally constructed for drainage line.
19.18.2 Excavation
The excavation for inspection chamber shall be true to dimensions and levels shown on the
plans or as directed by the Engineer-in-Charge.
19.18.3 Bed Concrete

The inspection chambers shall be built on a bed of cement concrete 1:5:10 (1 cement: 5 coarse
sand: 10 graded stone aggregate 40 mm nominal size) unless required by local authorities. The
thickness of the bed concrete shall be 15 cm unless otherwise specified or directed by the Engineer-
in-Charge and 40 mm thick cement concrete 1:2:4 ( 1 cement: 4 coarse sand: 4 grade stone aggregate
40 mm nominal size).
19.18.4 Brick Work

The brick work shall be with class 75 bricks in one brick thickness in cement mortar 1:4 (1
cement: 4 coarse sand). The external joints of the brick masonry shall be finished smooth, and the
joints of the pipes with the masonry shall be made perfectly leak proof.
19.18.5 Plaster and Pointing

The walls of the inspection chambers shall be plastered inside including bed with 12 mm thick
cement plaster 1:3 (1 cement: 3 coarse sand) finished smooth.
For earth work excavation, bed concrete, brick work, plaster and pointing, R.C.C. work and
refilling of earth, respective specifications shall be followed.
19.18.6 Inspection Chamber Covers and Frames

The frame of inspection chambers shall be firmly embedded to correct alignment and levels in
R.C.C. slab or plain concrete as the case may be on the top of the masonry. After completion of the
work, inspection chambers covers shall be sealed by means of thick grease.

Inspection chambers shall be enumerated under relevant items. The depth of the inspection chambers
shall be reckoned from the top level of C.I. cover to the invert level. The depth shall be measured
correct to a cm. The extra depth shall be measured and paid as extra over the specified depth.
19.18.8 Rate
above but excludes the cost of (i) excavation, (ii) 12 mm thick cement plaster with water proofing
material applied at the external surface of the inspection chambers if required (iii) 40 mm thick
cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 grade stone aggregate 40 mm nominal size).
These items shall be paid for separately under relevant items of work. Payment for extra depths of
inspection chambers shall be made separately under relevant items of work.
19.19. NON PRESSURE NP-3 CLASS (MEDIUM DUTY)/ NP-4 CLASS (HEAVY DUTY) R.C.C. PIPES
19.19.1 The pipes shall be with reinforcement as required and shall be of class not lesser than NP2.
These shall conform to IS 458 and shall be capable of withstanding a test pressure of 0.07 MPa (7 m
head). The reinforced cement concrete pipes shall be manufactured by centrifugal (or spun) process
or vibrated casting process. All pipes shall be true to shape, straight, perfectly sound and free from
cracks and flaws. The external and internal surface of the pipes shall be smooth and hard. The pipes
shall be free from defects resulting from imperfect grading of the aggregate mixing or moulding.
Concrete used for the manufacture of reinforced concrete pipes and collars shall be as per
design mix. The concrete quality (concrete mix, maximum water-cement ratio, minimum cement content.
etc) shall be as per IS 456 for at least very severe environment exposure condition with minimum
cement content 260 kg/m³. The maximum size of aggregate should not exceed one third of the
thickness of the pipe or 20 mm whichever is smaller for pipes above 250 mm internal diameter. But
for pipes of internal diameter 80 to 250 mm, the maximum size of aggregate should be 10mm. The
reinforcement in the reinforced concrete pipes shall extend throughout the length of the pipe. The
circumferential and longitudinal reinforcements shall be adequate to withstand the specified hydrostatic
pressure and further bending stresses due to the weight of water when running full across a span
equal to the length of pipe plus three times its own weight.
The Design/ dimensional requirements of concrete pipes are given in Appendix I A (collar for
NP2 pipe) and I B (for NP-2 pipe), Appendix I C (Collar for NP-3 & NP-4 pipe ), Appendix I D and 1 E
(for NP-3 pipe), Appendix I F and I G (for NP-4 pipe).
The minimum clear cover for reinforcement in pipes and collars shall be as given in Table 19.6.
TABLE 19.6
Sl . No. Precast concrete pipe/collar Minimum clear cover, mm

(i) Barrel wall thickness
(a) Upto and including 75 mm 8
(b) Over 75 mm 15
(ii) At spigot steps 5
(iii) At end of longitudinal 5
Note : An effective means shall be provided for maintaining the reinforcement in position and for
ensuring correct cover during manufacture of the unit. Spacers for this purpose shall be of rust proof
material or of steel protected against corrosion.

19.19.2 Laying and Jointing Cement Concrete Pipes and Specials
19.19.2.1 Trenches:
(i) Trenches shall be as described in 18.4.4. Where the pipes are to be bedded directly on
soil, the bed shall be suitably rounded to fit the lower part of the pipe, the cost for this
operation being included in the rate for laying the pipe itself.
(ii) Loading, transporting and unloading of concrete pipes shall be done with care. Handling
shall be such as to avoid impact. Gradual unloading by inclined plane or by chain
pulley block is recommended. All pipe sections and connections shall be inspected
carefully before being laid. Broken or defective pipes or connections shall not be used.
Pipes shall be lowered into the trenches carefully. Mechanical appliances may be used.
Pipes shall be laid true to line and grade as specified. Laying of pipes shall proceed
upgrade of a slope.
(iii) If the pipes have spigot and socket joints, the socket ends shall face upstream. In the
case of pipes with joints to be made with loose collars, the collars shall be slipped on
before the next pipe is laid. Adequate and proper expansion joints shall be provided
where directed.
(iv) In case where foundation conditions are unusual such as in the proximity of trees or
holes, under existing or proposed tracks manholes etc. the pipe shall be encased all-
around in 15 cm thick cement concrete 1:5:10 (1 cement : 5 fine sand : 10 graded stone
aggregate 40 mm nominal size) or compacted sand or gravel.
(v) In cases where the natural foundation is inadequate the pipes shall be laid either in
concrete cradle supported on proper foundations or on any other suitably designed
structure. If a concrete cradle bedding is used the depth of concrete below the bottom
of the pipe shall be at least 1/4th of the internal dia of the pipe subject to the min. of 10
cm and a maximum of 30 cm. The concrete shall extend up the sides of the pipe at least
to a distance of 1/4th of the outside diameter of pipes 300 mm and over in dia. The pipe
shall be laid in this concrete bedding before the concrete has set. Pipes laid in trenches
in earth shall be bedded evenly and firmly and as far up the haunches of the pipe as to
safely transmit the load expected from the backfill through the pipe to the bed. This
shall be done either by excavating the bottom of the trench to fit the curve of the pipe or
by compacting the earth under around the curve of the pipe to form an even bed.
Necessary provision shall be made for joints wherever required.
(vi) When the pipe is laid in a trench in rock hard clay, shale or other hard material the space
below the pipe shall be excavated and replaced with an equalising bed of concrete, sand
or compacted earth. In no place shall pipe be laid directly on such hard material.
(vii) The method of bedding and laying the pipes under different conditions are illustrated in
Fig. 19.9.
(viii) When the pipes are laid completely above the ground the foundations shall be made
even and sufficiently compacted to support the pipe line without any material settlement.
Alternatively the pipe line shall be supported on rigid foundations at intervals. Suitable
arrangements shall be made to retain the pipe line in the proper alignment, such as by
shaping the top of the supports to fit the lower part of the pipe. The distance between the
supports shall in no case exceed the length of the pipe. The pipe shall be supported as
far as possible close to the joints. In no case shall the joints come in the centre of the
span. Care shall be taken to see that super imposed loads greater than the total load
equivalent to the weight of the pipe when running full shall not be permitted. Suitably
designed anchor blocks at change of direction and grades for pressure lines shall be
provided where required.

19.19.2.2 Jointing:
Joints are generally of rigid type. Where specified flexible type joints may also be provided.
(a) Rigid Spigot and Socket Joint (Fig. 19.10): The spigot of each pipe shall be slipped home well into
the socket of the pipe previously laid and adjusted in the correct position. The opening of the joint
shall be filled with stiff mixture of cement mortar in the proportion of 1:2 (1 cement: 2 fine sand)
which shall be rammed with caulking tool. After a day’s work any extraneous material shall be
removed from the inside of the pipe and the newly made joint shall be cured.
(b) Rigid Collar Joint (Fig. 19.10): The two adjoining pipes shall be butted against each other and
adjusted in correct position. The collar shall then be slipped over the joint, covering equally both the
pipes. The annular space shall be filled with stiff mixture of cement mortar 1:2 (1 cement: 2 fine
sand) which shall be rammed with caulking fool. After a day’s work any extraneous materials shall
be removed from the inside of the pipe and the newly made joint shall be cured.
(c) Semi Flexible Spigot and Socket Joint (Fig. 19.10): The joint is composed of specially shaped
spigot and socket ends on the concrete pipes. A rubber ring shall be placed on the spigot which
shall be forced into the socket of the pipe previously laid. This compresses the rubber ring as it rolls
into the annular space formed between the two surfaces of the spigot and the socket, stiff mixture
of cement mortar 1:2 (1 cement: 2 fine sand) shall then be filled into the remaining annular space
and rammed with a caulking tool. After day’s work any extraneous materials shall be removed from
the inside of the pipe and the newly made joint shall be cured.
(d) Semi Flexible Collar Joint: This is made up of a loose collar which covers two specially shaped pipe
ends as shown in the Fig. 19.10. Each end shall be fitted with a rubber ring which when compressed
between the spigot and the collar, seal the joint. Stiff mixture of cement mortar 1:2 (1 cement: 2 fine
sand), shall then be filled into the remaining annular space and rammed with a caulking tool. After
day’s work, any extraneous material shall be removed from the inside of the pipe and the newly
made joint shall be cured.
(e) Internal Flush Joint (Fig. 19.10): This joint is generally used for culvert pipe of 60 cm dia and over.
The ends of the pipe are specially shaped to form a self centering joint with an internal jointing
space 1.3 cm wide the finished joint is flush with both inside and outside with the pipe wall as
shown in Fig. 19.10. The jointing space is filled with cement mortar 1:2 (1 cement: 2 fine sand)
mixed sufficiently dry to remain in position when forced with a trowel or rammer. After day’s work,
any extraneous material shall be removed from the inside of the pipe and the newly made joint shall
be cured.
(f) External Flush Joint : This joint is suitable for pipes which are too small for jointing from inside. This
joint is composed of specially shaped pipe ends as shown in Fig. 19.10. Each end shall be butted
against each other and adjusted in correct position. The jointing space shall then be filled with
cement mortar 1:2 (1 cement: 2 fine sand) sufficiently dry and finished off flush. Great care shall be
taken to ensure that the projecting ends are not damaged as no repairs can be readily affected from
inside the pipe.
19.19.2.3 In all pressure pipe lines the recess at the end of the pipe line shall be filled with jute braiding
dipped in hot bitumen or other suitable approved compound. Pipes shall be so jointed that the bitumen ring of
one pipe shall set into the recess of the next pipe. The ring shall be thoroughly compressed by jacking or by
any other suitable method.
The number of pipes that shall be jacked together at a time shall depend on the diameter of the pipes
and the bearing capacity of the soil, for small pipes up to 25 cm diameter, six pipes can be jacked
together at a time.
The quantity of jute and bitumen in the ring shall be just sufficient to fill the recess in the pipe when
pressed hard by jacking or by any other suitable method. Before and during jacking care shall be taken to see
that there is no offset at the joint.

19.19.2.4 Testing: For pressure pipes, the completed pipeline shall be tested for pressure (Known
as site test pressure) which shall not be less than the maximum pipeline operating pressure plus the
calculated surge pressure, but in no case shall it exceed the hydrostatic test pressure. For non
pressure pipes the joints shall be tested as per procedure laid down under Para 19.2.1.2 (iv).
19.19.2.5 Refilling of Trenches:

The specification described in 19.2.1.2 (v) shall apply. In case where pipes are not bedded on
concrete special care shall be taken in refilling, trenches to prevent the displacement and subsequent
settlement at the surface resulting in uneven street surfaces and dangers to foundations etc. The
backfilling materials shall be packed by hand under and around the pipe and rammed with a shovel
and light tamper. This method of filling will be continued up to the top of pipe. The refilling shall rise
evenly on both sides of the pipe and continued up to 60 cm above the top of pipe so as not to disturb
the pipe. No tamping shall be done within 15 cm of the top of pipe. The tamping shall become
progressively heavier as the depth of the backfill increases.
The lengths of pipes shall be measured in running metres nearest to a cm as laid or fixed, from
inside of one manhole to the inside of the other manhole. The length shall be taken along the centre
line of the pipes over all fittings such as bends, collars, junctions, etc. which shall not be measured
separately.
Excavation, refilling, shoring and timbering in trenches, and cement concreting wherever required
shall be measured separately under relevant items of work.
19.19.4 Rate:
above.

APPENDIX – ‘I’
A: DIMENSIONAL REQUIREMENT OF CLASS NP2-REINFORCED CONCRETE LIGHT DUTY,

NON PRESSURE PIPES & COLLAR
(Clause 19.2.2)
Nominal Barrel Wall Collar Dimensions Reinforcements in Collar
Internal Thickness Minimum Minimum Minimum Longitudinal, Mild Spiral Hard
Diameter of pipe Caulking Thickness Length steel or Hard Drawn Drawn
of Pipe Space Steel Steel
Minimum Weight
mm mm mm mm mm Number Kg/Collar Kg/Collar
(1) (2) (3) (4) (5) (6) (7) (8)
80 25 13 25 150 6 0.08 0.07
100 25 13 25 150 6 0.08 0.08
150 25 13 25 150 6 0.08 0.10
200 25 13 25 150 6 0.08 0.12
225 25 13 25 150 6 0.08 0.14
250 25 13 25 150 6 0.08 0.16
300 30 16 30 150 8 0.11 0.22
350 32 16 32 150 8 0.11 0.25
400 32 16 32 150 8 0.11 0.27
450 35 19 35 200 8 0.15 0.40
500 35 19 35 200 8 0.15 0.60
600 45 19 40 200 8 0.15 0.70
700 50 19 40 200 8 0.23 1.05
800 50 19 45 200 8 0.23 1.85
900 55 19 50 200 8 0.23 2.05
1000 60 19 55 200 8 0.33 2.25
1100 65 19 60 200 8 0.33 3.09
1200 70 19 65 200 8 0.33 4.11
1400 75 19 75 200 12 0.50 5.08
1600 80 19 80 200 12 or 8+8 0.67 6.55
1800 90 19 90 200 12 or 8+8 0.67 9.00
2000 100 19 100 200 12+12 1.00 12.15
2200 110 19 110 200 12+12 1.00 13.30
Note:
1. If the mild steel is used for spiral reinforcement, the weight specified under col. 7 shall be
increased by a factor 140/25.
2. Soft grade mild steel wire may be used as reinforcement for collars of pipes of nominal
internal diameter up to 250 mm only, by increasing the weight by a factor 140/84. Where
only soft grade mild steel wire is used for making collar cages, the weight of reinforcement
shall be total weight or col. 6 and 7 multiplied by 140/84. This is allowed as a process
requirement.
3. Internal diameter of collar to suit the actual diameter of pipes with minimum caulking space
as given in col. 2

B: REINFORCED CONCRETE PRESSURE PIPES CLASS P1 TESTED TO 20 m
HEAD, CLASS P2 TESTED TO 40 m HEAD AND CLASS P3 TESTED TO 60 m HEAD
Internal diameter Barrel dimension
of pipes Class P1 Class P2 Class P3
(mm) (mm) (mm) (mm)
80 25 25 25
100 25 25 25
150 25 25 25
200 25 30 35
225 25 30 35
250 25 30 35
300 30 40 45
350 32 45 55
400 32 50 60
450 35 50 70
500 35 55 75
600 40 65 90
700 40 70 105
800 45 80 120
900 50 90 -
1000 55 100 -
1100 60 - -
1200 65 - -
Notes :
1. The effective length of barrel shall be 2 m up to 250 mm nominal diameter pipes and 2.5, 3.0,
3.5 or 4.0 m for pipes above 250 mm.
2. Collar dimensions will be same as specified for class NP2 pipes.

APPENDIX — ‘I A’
C: Table 21 DESIGN REQUIREMENT OF REINFORCED CONCRETE COLLAR FOR PIPE OF

CLASS NP-2 (Clause 19.19)
( Clause 6.3 and 8.1 of IS 458:2003)
Nominal Collar Dimensions Reinforcements in Collar
Internal Minimum Minimum Minimum Longitudinal, Mild steel or Spiral Hard
Diameter Caulking Thickness Length Hard Drawn Steel Drawn Steel
of Pipe Space
mm mm mm mm Minimum Weight Kg/Collar
Number
Kg/Collar
(1) (3) (4) (5) (6) (7) (8)
80 13 25 150 6 0.08 0.07
100 13 25 150 6 0.08 0.08
150 13 25 150 6 0.08 0.10
200 13 25 150 6 0.08 0.12
225 13 25 150 6 0.08 0.14
250 13 25 150 6 0.08 0.16
300 16 30 150 8 0.11 0.22
350 16 32 150 8 0.11 0.25
400 16 32 150 8 0.11 0.27
450 19 35 200 8 0.15 0.40
500 19 35 200 8 0.15 0.60
600 19 40 200 8 0.15 0.70
700 19 40 200 8 0.23 1.05
800 19 45 200 8 0.23 1.85
900 19 50 200 8 0.23 2.05
1000 19 55 200 8 0.33 2.25
1100 19 60 200 8 0.33 3.09
1200 19 65 200 8 0.33 4.11
1400 19 75 200 12 0.50 5.08
1600 19 80 200 12 or 8+8 0.67 6.55
1800 19 90 200 12 or 8+8 0.67 9.00
2000 19 100 200 12+12 1.00 12.15
2200 19 110 200 12+12 1.00 13.30
Note:
1. If the mild steel is used for spiral reinforcement, the weight specified under col. 7 shall be
increased by a factor 140/125.
2. Soft grade mild steel wire may be used as reinforcement for collars of pipes of nominal
internal diameter up to 250 mm only, by increasing the weight by a factor 140/84. Where only
soft grade mild steel wire is used for making collar cages, the weight of reinforcement shall be
total weight or col. 6 and 7 multiplied by 140/84. This is allowed as a process requirement.
3. Internal diameter of collar to suit the actual diameter of pipes with minimum caulking space as
given in col. 2

APPENDIX-‘I B’
D: Table 2 Design and Strength Test Requirements of Concrete Pipes of Class NP2-
Reinforced Concrete, Light Duty, Non-pressure Pipes (Clause 19.19)
(Clauses 6.1.1, 6.1.2.1, 6.1.3, 6.2.2, 7.3.2, 8.1 and Table 20 of IS 458:2003)
Internal Barred wall Reinforcements Strength Test requirements for
Diameter Thickness Three Edge Bearing Test.
of Pipes Longitudinal, Mild Steel or Spiral Hard Load to Ultimate Load
Hard Drawn Steel Drawn Steel Produce 0.25
mm Crack
mm mm Minimum Kg/linear kg/linear kN/linear metre kN/linear metre
Number metre metre
(1) (2) (3) (4) (5) (6) (7)
80 25 6 0.59 0.16 10.05 15.08
100 25 6 0.59 0.18 10.05 15.08
150 25 6 0.59 0.24 10.79 16.19
200 25 6 0.59 0.38 11.77 17.66
225 25 6 0.59 0.46 12.26 18.39
250 25 6 0.59 0.58 12.55 18.83
300 30 8 0.78 0.79 13.48 20.22
350 32 8 0.78 1.13 14.46 21.69
400 32 8 0.78 1.49 15.45 23.18
450 35 8 0.78 1.97 16.18 24.27
500 35 8 0.78 2.46 17.16 25.74
600 45 8 0.78 3.47 18.88 28.32
700 50 8 1.22 4.60 20.35 30.53
800 50 8 1.22 6.71 21.57 32.36
900 55 8 1.22 9.25 22.80 34.20
1000 60 8 1.76 10.69 24.27 36.41
1100 65 8 1.76 12.74 25.50 38.25
1200 70 8 1.76 15.47 26.97 40.46
1400 75 12 2.64 20.57 29.42 44.13
1600 80 12 or 8+8 3.52 25.40 32.12 48.18
1800 90 12 or 8+8 3.52 32.74 35.06 52.59
2000 100 12+12 5.28 45.14 37.76 56.64
2200 110 12+12 5.28 56.37 40.21 60.32
NOTES
1. lf mild steel is used for spiral reinforcement, the weight specified under col. 5 shall be increased
to 140/125.
2. Soft grade mild steel wire for spirals may be used for pipes of internal diameters 80 mm,
100 mm and 150 mm only by increasing weight to 140/84.
3. The longitudinal reinforcement given in this table is valid for pipes up to 25m effective length
for internal diameter of pipe up to 250mm up to 3m effective length for higher diameter pipe.
4. Total mass of longitudinal reinforcement shall be calculated by multiplying the values given in
col. 4 by the length of the pipe and then deducting for the cover length provided at the two
ends.

APPENDIX-‘I C’
E: Table 22 Design Requirements of Reinforced Concrete Collars for Pipes of

Class NP3 and NP4
(Clauses 6.3 and 8.1 of IS 458:2003)
Nominal Collar Dimensions Reinforcements
Internal Minimum Minimum Minimum Longitudinal, Mild Steel or Spiral Hard
Diameter of caulking Thickness Length Hard Drawn Steel Drawn Steel
pipe Space
mm mm mm mm Nos Kg/collar Kg/collar
(1) (2) (3) (4) (5) (6) (7)
90 13 25 150 6 0.08 0.07
100 13 25 150 6 0.08 0.08
150 13 25 150 6 0.08 0.10
200 13 25 150 6 0.08 0.12
225 13 25 150 6 0.08 0.14
250 13 25 150 6 0.08 0.16
300 16 30 150 8 0.11 0.22
350 19 35 200 8 0.15 0.40
400 19 35 200 8 0.15 0.50
450 19 35 200 8 0.15 0.60
500 19 40 200 8 0.15 0.70
600 19 40 200 8 0.23 1.05
700 19 45 200 8 0.23 1.85
800 19 50 200 8 0.23 2.05
900 19 55 200 8 0.33 2.25
1000 19 60 200 8 0.33 3.09
1100 19 65 200 8 0.33 4.11
1200 19 75 200 12 0.50 5.08
1400 19 80 200 12 or 8+8 0.67 6.55
1600 19 90 200 12 or 8+8 0.67 9.00
1800 19 100 200 12 +12 1.00 12.15
2000 19 110 200 12 +12 1.00 13.30

APPENDIX-‘I D’
F: Table 3 Design and Strength Test Requirements of Concrete Pipes of Class NP3-
Reinforced Concrete, Medium Duty, Non-pressure Pipes
( Clauses 6.1.1, 6.1.2, 6.1.3, 6.2.2, 7.3.2, 8.1 and Table 20 of IS 458:2003)
Internal Barred Reinforcements Strength Test requirements for
Diameter wall Three Edge Bearing Test.
of Pipes Thickness Longitudinal, Mild Steel Spiral Hard Load to Ultimate Load
or Hard Drawn Steel Drawn Produce 0.25
Steel mm Crack
mm mm Minimum kg/linear kg/linear kN/linear kN/linear metre
Number metre metre metre
(1) (2) (3) (4) (5) (6) (7)
80 25 6 0.59 0.16 13.00 19.50
100 25 6 0.59 0.22 13.00 19.50
150 25 6 0.59 0.46 13.70 20.55
200 30 6 0.59 0.81 14.50 21.75
225 30 6 0.59 1.03 14.80 22.20
250 30 6 0.59 1.24 15.00 22.50
300 40 8 0.78 1.80 15.50 23.25
350 75 8 0.78 2.95 16.77 25.16
400 75 8 0.78 3.30 19.16 28.74
450 75 8 0.78 3.79 21.56 32.34
500 75 8 0.78 4.82 23.95 35.93
600 85 8 or 6+6 1.18 7.01 28.74 43.11
700 85 8 or 6+6 1.18 10.27 33.53 50.30
800 95 8 or 6+6 2.66 13.04 38.32 57.48
900 100 6+6 2.66 18.30 43.11 64.67
1000 115 6+6 2.66 21.52 47.90 71.85
1100 115 6+6 2.66 27.99 52.69 79.00
1200 120 8+8 3.55 33.57 57.48 86.22
1400 135 8+8 3.55 46.21 67.06 100.60
1600 140 8+8 3.55 65.40 76.64 114.96
1800 150 12+12 9.36 87.10 86.22 129.33
2000 170 12+12 9.36 97.90 95.80 143.70
2200 185 12+12 9.36 133.30 105.38 158.07
2400 200 12+12 14.88 146.61 114.96 172.44
2600 215 12+12 14.88 175.76 124.54 186.81
NOTES
1. If mild steel is used for spiral reinforcement, the weight specified under col 5 shall be increased
to 140/125.
for internal diameter of pipe up to 250 mm and up to 3m effective length for higher diameter
pipes.
3. Total mass of longitudinal reinforcement Shall be calculated by multiplying the values given
in col 4 by the length of the pipe and then deducting for the cover length provided at the two
ends.
4. Concrete for pipes shall have a minimum compressive strength of 35 N/mm2 at 28 days

APPENDIX-‘I E’
G: Table 5 Design and Strength Test Requirements of Concrete Pipes of Class NP3-
Reinforced Concrete, Medium Duty, Non-pressure Pipes made by
Vibrated Casting Process
(Clauses 5.5.1, 6.1.1, 6.1.2.1, 6.1.3, 6.2.2, 7.3.2, 8.1 and Table 20 of IS 458:2003)
Internal Minimum Reinforcements Strength Test requirements for

Diameter Barred Three Edge Bearing Test.
of Pipes Thickness Longitudinal, Mild Steel or Spiral Hard Load to Ultimate Load
mm Crack
Number metre metre
(1) (2) (3) (4) (5) (6) (7)
300 50 8 0.78 1.53 15.50 23.25
350 55 8 0.78 1.58 16.77 25.16
400 60 8 0.78 1.60 19.16 28.74
450 65 8 0.78 1.90 21.56 32.34
500 70 8 0.78 2.00 23.95 35.93
600 75 8 or 6+6 1.18 2.20 28.74 43.11
700 85 8 or 6+6 1.18 4.87 33.53 50.30
800 95 8 or 6+6 2.66 6.87 38.32 57.48
900 100 6+6 2.66 11.55 43.11 64.67
1000 115 6+6 2.66 15.70 47.90 71.85
1100 120 6+6 2.66 19.61 52.69 79.00
1200 125 8+8 3.55 21.25 57.48 86.22
1400 140 8+8 3.55 30.00 67.06 100.60
1600 165 8+8 3.55 50.63 76.64 114.96
1800 180 12+12 9.36 64.19 86.22 129.33
2000 190 12+12 9.36 83.12 95.80 143.70
2200 210 12+12 9.36 105.53 105.40 158.07
2400 225 12+12 14.88 133.30 115.00 172.44
NOTE — Concrete for pipes shall have a minimum compressive strength or 35 N/mm2 at 28 days

APPENDIX-‘I F’
H: Table 6 Design and Strength Test Requirements of Concrete Pipes of Class NP4-
Reinforced Concrete, Medium Duty, Non-pressure Pipes
(Clauses 6.1.1, 6.1.2, 6.1.3, 6.2.2, 7.3.2, 8.1 and Table 20 of IS 458:2003)
mm Crack
mm mm Minimum kg/linear kg/linear kN/linear metre kN/linear metre
Number metre metre
(1) (2) (3) (4) (5) (6) (7)
80 25 6 0.59 0.24 22.10 33.15
100 25 6 0.59 0.36 22.10 33.15
150 25 6 0.59 0.74 22.30 34.95
200 30 6 0.59 1.30 24.60 36.90
225 30 6 0.59 1.64 25.20 37.80
250 30 6 0.59 1.98 25.50 38.25
300 40 8 0.78 2.71 26.40 39.60
350 75 8 0.78 3.14 29.80 44.70
400 75 8 0.78 3.52 33.90 50.90
450 75 8 0.78 3.88 36.90 55.30
500 75 8 0.78 5.96 40.00 61.20
600 85 8 or 6+6 2.34 9.63 46.30 69.40
700 85 8 or 6+6 3.44 14.33 52.20 78.30
800 95 8 or 6+6 3.44 21.20 59.30 79.10
900 100 6+6 3.34 27.13 66.30 99.40
1000 115 8+8 6.04 35.48 72.60 108.90
1100 115 8+8 6.04 43.76 80.40 120.60
1200 120 8+8 6.04 53.07 88.30 132.40
1400 135 8+8 9.36 77.62 104.20 156.40
1600 140 12+12 9.36 108.97 119.60 179.50
1800 150 12+12 14.88 150.22 135.30 203.00
2000 170 12+12 14.88 151.79 135.30 203.00
2200 185 12+12 14.88 160.90 142.20 213.30
2400 200 12+12 14.88 216.96 155.00 232.50
2600 215 12+12 14.88 258.93 166.70 250.00
NOTES
1. If mild Steel is used for spiral reinforcement, the weight specified under col 5 shall be increased
to 140/125.
for internal diameter of pipe up to 250 mm and 3 m effective length for higher diameter pipes.
3. The total mass of longitudinal reinforcement shall be calculated by multiplying the values
given in col 4 by the length of the pipe and then deducting for the cover length provided at
the Iwo ends.
4. Concrete for pipes shall have a minimum compressive strength of 35 N/mm2 at 28 days.

APPENDIX-‘I G’
I: Table 8 Design and Strength Test Requirements of Concrete Pipes of Class NP4-
Reinforced Concrete, Heavy Duty, Non-pressure Pipes made by Vibrated Casting Process
(Clauses 5.5.1, 6.1.1, 6.1.2.1, 6.1.3, 6.2.2, 7.3.2, 8.1 and Table 20 of IS 458:2003)
mm Crack
Number metre metre
(1) (2) (3) (4) (5) (6) (7)
300 50 8 0.78 1.53 26.40 38.60
350 55 8 0.78 1.61 29.80 44.70
400 60 8 0.78 1.97 33.90 50.90
450 65 8 0.78 3.36 36.90 55.30
500 70 8 0.78 5.56 40.00 61.20
600 75 8 or 6+6 2.34 8.50 46.30 69.40
700 85 8 or 6+6 3.44 12.78 52.20 78.30
800 95 8 or 6+6 3.44 16.72 59.30 89.10
900 100 6+6 3.44 20.92 66.30 99.40
1000 115 8+8 6.04 26.70 72.60 108.90
1100 120 8+8 6.04 35.60 80.40 120.60
1200 125 8+8 6.04 42.42 88.30 132.40
1400 140 8+8 9.36 53.39 104.20 156.40
1600 165 12+12 9.36 79.92 119.60 179.50
1800 180 12+12 14.88 85.75 135.30 203.00
2000 190 12+12 14.88 108.00 135.30 203.00
NOTES: - Concrete for pipe shall have a minimum compressive strength of 35 N/mm2 at 28 days
Marking
The following information shall he clearly marked on each pipe/collar:
(a) Indication of the source of manufacture.
(b) Class and Size of pipe/collar.
(c) The words ‘SPUN PIPE’ or ‘VIBRATED CAST PIPE (UNREINFORCED)’ or ‘VIBRATED CAST
PIPE (REINFORCED)’ as may be applicable, for pipes; and
(d) Date of manufacture
The above information shall be clearly marked on outside only for pipes up to and including 350
mm internal diameter, and both outside and inside for pipes above 350 mm internal diameter. The
information shall be clearly marked only on the outside for collars.
‘Each pipe/collar may also be marked with the Standard Mark’

The Number of tests and criteria for conformity shall be as given in table 22 of IS 458:2003
Table 22 Scale of Sampling and Permissible number of Defectives.
(Clauses 11.1.3, 11.2.1.1 and 11.2.2 of IS 458:2003)

No. of Pipes in the For Requirement Under Clauses 8 and 9 of Sample Size for Test Under
Lot IS 458:2003 clause 10.2 of IS 458:2003
Sample Size Permissible Number (Excluding Ultimate Load Test)
or Defectives
(1) (2) (3) (4)
Up to 50 8 0 2
51 to 100 13 1 3
101 to 300 20 2 5
301 to 500 32 3 7
501 and above 50 5 10
The Lot shall be declared as conforming to these requirements if the number of defectives found
in the sample does not exceed the number of defectives given in col. 3 of Table 22.
Tolerances: (As per IS 458:2003 Para 8.2)

The following tolerances shall be permitted:
Sl. No. Dimensions Tolerances
(i) Overall length ± 1 percent of standard length
(ii) Internal diameter of pipes:
(a) Up to and including 300 ± 3 mm
(b) Over 300 mm and up to and including 600 mm ± 5 mm
(c) Over 600 mm ± 10 mm
(iii) Barrel wall thickness:
(a) Up to and including 30 mm +2 mm
-1 mm
(b) Over 30 mm up to and including 50 mm +3 mm
-1.5 mm
(c) Over 50 mm up to and including 65 mm +4 mm
-2 mm
(d) Over 65 mm up to and including 80 mm +5 mm
-2.5 mm
(e) Over 80 mm up to and including 95 mm +6 mm
-3 mm
(f) Over 95 mm +7 mm
-3.5 mm
Note- In case of pipes with flexible rubber ring joints, the tolerance on thickness near the ends will
have to be reduced. Near the rubber ring joints, the tolerance on thickness shall be as given in
tables 13 to 19 of IS 458:2003 in case of pipes manufactured by spinning process and as given in
table 15 and table 16 of IS 458:2003 in case of pipes manufactured by vibrated casting process.

APPENDIX — ‘II’
RECOMMENDED SIZES OF SEPTIC TANKS

(Clause 19.9)
RECOMMENDED SIZES OF SEPTIC TANKS FOR 5-20 USERS
No of users Length Breath Liquid depth (cleaning interval of)
1 year 2 year
(m) (m) (m) (m)
05 1.5 0.75 1.0 1.05
10 2.0 0.90 1.0 1.40
15 2.0 0.90 1.3 2.00
20 2.3 1.10 1.3 1.80
Notes :
1. The capacities are recommended on the assumption that discharges from only WC will be treated in
the septic tank.
2. A provision of 300 mm should be made for free board.
3. The sizes of septic tanks are based on certain assumptions, while choosing the size of septic tank
exact calculation shall be made.
RECOMMENDED SIZES OF SEPTIC TANKS FOR RESIDENTIAL COLONIES

No of users Length Breath Liquid depth (cleaning interval of)
1 year 2 year
(m) (m) (m) (m)
050 5.0 2.0 1.0 1.24
100 7.5 2.65 1.0 1.24
150 10.0 3.0 1.0 1.24
200 12.0 3.3 1.0 1.24
300 15.0 4.0 1.0 1.24
Notes :
2. The sizes of the septic tank are based on certain assumptions while choosing the size of septic tank,
exact calculation shall be made.
3. For population over 100, the tank may be divided into independent parallel chambers for ease of
maintenance and cleaning.
RECOMMENDED SIZES OF SEPTIC TANKS FOR HOSTEL AND BOARDING SCHOOLS

No of users Length Breath Liquid depth (D) for stated intervals of
sludge withdrawal
Once in a year Once in 2 year
(m) (m) (m) (m)
50 5.0 1.6 1.3 1.4
100 5.7 2.1 1.4 1.7
150 7.7 2.4 1.4 1.7
200 8.9 2.7 1.4 1.7
300 10.7 3.3 1.4 1.7
Notes :
2. The sizes of the septic tank are based on certain assumptions while choosing the size of
septic tank exact calculation shall be made.
3. For population over 100, the tank may be divided into independent parallel chambers for
ease of maintenance and cleaning.

FLUSHING TANK
Sub Head : Drainage

Clause : 19.0

Fig. 19.1 : Flushing Tank

GULLY TRAP
Sub Head : Drainage

Clause : 19.8
Typ e Size A C d D D E F F G
1 0 0 x1 0 0 305 175 100 100 100 65 – – 330
1 2 5 x1 0 0 265 165 100 125 100 60 – – 345
P 1 5 0 x1 0 0 330 165 100 150 100 75 – – 346
1 8 0 x1 0 0 320 200 100 180 100 65 – – 380
1 8 0 x1 5 0 405 270 150 180 150 75 – – 520

Q 1 2 5 x1 0 0 330 165 100 125 100 – 80 – 345
1 2 5 x1 0 0 290 165 100 125 100 – – 100 345
S 1 5 0 x1 0 0 330 165 100 150 100 – – 11 5 346

1 8 0 x1 5 0 445 275 150 180 150 – – 125 520

Fig. 19.2 : Gully Trap

MANHOLE
Sub Head : Drainage

Clause : 19.4

Fig. 19.3 : Manhole

MANHOLE (Contd.)
Sub Head : Drain

inage
Clause : 19.4

Fig. 19.4 : Manhole (Contd.)

MANHOLE (Contd.)
Sub Head : Drainage

Clause : 19.4


MANHOLE (Contd.)
Sub Head : Drainage

Clause : 19.4
W — Width of Wall
H — Height of spring of arch above the benching level
T = Thickness of foundation concrete


MANHOLE (Contd.)
Sub Head : Drainage

Clause : 19.4
H- Height of wall
T – Thickness of wall
D – Dia of manhole
d – Dia of pile
dc – Depth of bed Conc.
Dia of Bed Remarks

manhole H1 Conc
H2 H3 H4 H5 T1 T2 T3 T4 T5 dc
900 750 Depth - - - 1 BK 1 BK - - - 226 The soling will
Variable be provided
up to 750 where the site
1200 1350 -do- - - - 1 BK 1 BK - - - 300 Engineer will
1500 1950 750 2100 4050 Depth 1 BK 1½Bk 300 feel
variable necessary.
up to
4000 2 Bk 2½Bk 3Bk
1800 1950 750 2250 4050 –do– 1Bk 1½Bk 2 Bk 2½Bk 3 Bk 300


MANHOLE
(With Drop Connections)
Sub Head : Drainage

Clause : 19.4 & 19.5

Fig. 19.8 : Manhole (With Drop Connnections)

BEDDING OF PIPES
Sub Head : Drainage

Clause : 19.2.2.1

Fig. 19.9 : Bedding of Pipes

JOINTS OF CONCRETE PIPES
Sub Head : Drainage
Clause : 19.2.2.1
Fig. 19.10 : Joints of Concrete Pipes

BEDDING/ENCASING STONEWARE PIPES
Sub Head : Drainage

Clause : 19.2.1
(i) CONCRETE BEDDING
(ii) CONCRETE UPTO HAUNCHES
(iii) CONCRETE ALLROUND
W = D+X, Where D is the External Diametre of the pipe

X = 300 up to Trench Depth of 1200
= 400 Trench Depth more than 1200
T = 100 for pipes under 150, 1/4th Internal dia subjected to a min. of 150mm and max. 300 mm for pipes more than 150 Dia
MWL = Maximum water level

Fig. 19.11: Bedding/Encasing Stoneware Pipes

BRICK MASONRY OPEN SURFACE DRAINS
Sub Head : Drainage

Clause : 19.6

Fig. 19.12 : Brick Masonry Open Surface Drains

R.C.C ROAD GULLY GRATING
Sub Head : Drainage

Clause : 19.2.4 & 19.7.1
1. Drg. Not to Scale

2. All Dimensions are in mm
3. Clear Cover over Reinforcement shall be 20 mm
4. The Slab Covers shall Cast in R.C.C. 1:1:2
5. The R.C.C.. Cover shall be Properly Cured
Fig. 19.13: R.C.C. Road Gully Grating

R.C.C. ROAD GULLY CHAMBER
Sub Head : Drainage
Clause : 19.7

Fig. 19.14 : Road Gully Chamber

SEPTIC TANK
Sub Head : Drainage

Clause : 19.9

Fig. 19.15 : Septic Tank

SEPTIC TANK (Contd.)
Sub Head : Drainage
Clause : 19.9

Fig. 19.16 : Septic Tank (Contd.)

SOAK PIT
Sub Head : Drainage
Clause : 19.10

Fig. 19.17 : Soak Pit

DISPERSION TRENCH
Sub Head : Drainage
Clause : 19.12

Fig. 19.18 : Dispersion Trench

6MM THICK PLASTIC ENCAPSULATED M.S. FOOTREST AS PER IS:10910
Sub Head: Drainage

Clause: 19.15
NOTE: ALL DIMENSIONS ARE IN MM

Fig.19.19 6mm thick Plastic Encapsulated M.S. Footrest as per IS:10910

CHAMBER DETAILS
610X455 with Light Duty Cover
Sub Head: Drainage
Clause:19.18
PLAN

Fig. 19.20 610X455 with Light Duty Cover

CHAMBER DETAILS
700X500 with Medium Duty Cover
Sub Head: Drainage
Clause:19.18
PLAN
BAR BENDING SCHEDULE

MARK DIA (mm) Numbers Length
a 10 4 920
b 10 3 1120
c 10 6 280
d 10 8 230
Fig. 19.21 700X500 with Medium Duty Cover

CHAMBER DETAILS
850X600 with Medium Duty Cover
Sub Head: Drainage
Clause:19.18
PLAN
BAR BENDING SCHEDULE

MARK DIA (mm) Numbers Length
a 10 5 1020
b 10 4 1270
c 10 6 430
d 10 7 330
Fig.19.22 850X600 with Medium Duty Cover

SUB HEAD : 20.0
PILE WORK
1075
CONTENTS
20.1 Driven Cast-in-situ Reinforced Concrete Piles 1081
20.2 Bored Cast-in-situ Reinforced Concrete Piles 1088
20.3 Under-reamed RCC Piles 1090
20.4 Driven Pre-cast RCC Piles 1097
20.5 Load Test on Piles 1104
Appendix A Basic Properties of Drilling Mud (Bentonite) 1108
Appendix B Equipments for Under-reamed Piles 1109

(Manual Construction)
Appendix C Pile Frame 1110
Appendix D Pile Boring Equipment-General Requirement 1111
Appendix E Cyclic Load Test Method 1116
Appendix F Pile Driving Hammer 1118
Fig. 20.1 Different Types of Pile Shoes 1082
Fig. 20.2 Pedestal Piles 1095
Fig. 20.3 Cap for Two Piles (Typical) 1096
Fig. 20.3.8 Section of interior beam in expansive soils 1097

Grade Beams Section Of Exterior Beam In Expansive Soils
Fig. D1 Pile boring equipment- general requirement 1112

(Clause
20.2.2)
Fig. D-2 Sludge pump (shell) 1114
Fig. D-3 Bailer 1114
1077 SUB HEAD 20.0 : PILE WORK


1. IS-1200 (Part 23) Method of measurement of building and Civil Engineering
Works - Piling.
2. IS-2911 (Part 1/Sec. 1) Code of practice for Design and Construction of pile
foundation. Driven cast-in-situ piles.
3. IS-2911 (Part 1/Sec. 2) Code of practice of Design and Construction of pile
foundation. Bored Cast-in-situ piles.
foundation. Driven pre-cast concrete piles.
foundation. Bored pre-cast concrete piles.
6. IS-2911 (Part 3) Code of practice for Design and Construction of pile
foundation. Under reamed piles.
7. IS-2911 (Part 4) Code of practice for design and Construction of pile
foundation. Load test on piles.
8. IS-5112 Safety Code for piling and other deep foundations.
9. IS-6426 Specification for pile driving hammer.
10. IS-6427 Glossary of terms relating to pile driving.
11. IS-6428 Specification for pile frame.
12. IS-9716 Guide for lateral dynamic load test on piles.
13. IS-14362 Pile boring equipments. General requirements.

20.0 PILE WORK
20.0 TERMINOLOGY
Allowable Load: It is load which is applied to a pile after taking into account its ultimate load capacity,
pile spacing, Overall bearing capacity of the ground, the allowable settlement, negative skin friction
including reversal of loads.
Bearing Pile: A pile formed in the ground for transmitting load of a structure to the soil by the
resistance developed at its tips and or along its surface. It is either vertical or batter pile. It may be
‘End bearing pile’ or friction pile if it supports the load primarily along the surface.
Board Compaction Pile: It is bored cast- in-situ with or without bulb. In this compaction of surrounding
ground and freshly filled concrete in pile, bore is simultaneously achieved by suitable method. A pile
with a bulb is called a “under-reamed bored compaction pile”. Under-reamed pile with more than one
bulb is called Multi-under-reamed pile.
Constant Rate of Penetration (CRP) Test: The ultimate bearing capacity of preliminary piles and
piles which are not used as working piles.
Constant Rate of Uplift (CRU) Test: The ultimate capacity in tension of preliminary piles and piles
which are not used as working piles.
Cut of Level: It is the level where the installed pile is cut off to support the pile caps or beams.
Datum Bar: A rigid bar placed on immovable supports.
Draft Bolt: A metal rod driven into hole bored in timber, the hole being smaller in diameter than the
rod.
Drop of Stroke: The distance through which the driving weight is allowed to fall for driving the piles.
Factor of Safety: It is the ratio of the ultimate load capacity of a pile to the safe load of a pile.
Follower Tube: A tube which is used following the main casing tube and it requires to be extended
further. The inner diameter of the follower tube should be the same as the inner diameter of casing.
The follower tube shall preferably be an outside guide and should be water tight when driven in
water-bearing strata or soft clays.
Initial Test: This test is carried out with a view to determine ultimate load capacity and safe load
capacity.
Raker or Batter Pile: The pile which is installed at an angle to the vertical. Raker piles are normally
provided where vertical piles cannot resist the required applied horizontal forces. The maximum rake
to be permitted in piles shall not exceed –
1 in 8 for cast-in-situ piles of large diameter viz. 750 mm dia,. and above.
1 in 5 for smaller dia. cast-on-situ piles.
1 in 4 pre-cast piles.
Routine Test: It is carried out with a view to check whether pile is capable of taking the working load
assigned to it.

Safe Load: It is the load arrived at by applying a factor of safety to the ultimate load capacity of the
pile.
Set: The net distance by which the pile penetrates in the ground due to stated number of blows of
the hammer.
Spliced Pile: A pile composed of two or more lengths secured together, end to end to form one pile.
Test Pile: A pile which is selected for load testing and which is subsequently loaded for that purpose.
This pile may form working pile itself if subjected to a routine load test with up to one and half time the
safe load.
Total displacement (Gross): The total movement of the pile under a given load.
Total Elastic Displacement: This is the magnitude of the displacement of the pile due to rebound
caused at the top after removal of given test load. This comprises two components as follows:
(a) Elastic displacement of the soil participating in load transfer; and
(b) Elastic displacement of the pile shaft.
Trial Piles: These are installed initially to assess the load carrying capacity, it is either tested to
ultimate bearing capacity or twice the estimated safe load.
Ultimate Load Capacity: The maximum load which a pile can carry before failure of ground (when
the soil fails by shear) or failure of pile materials.
Working Load: It is a load assigned to a pile as per design.
Working Pile: It is a pile forming part of foundation of a structural system.
20.1 DRIVEN CAST-IN-SITU REINFORCED CEMENT CONCRETE PILES

20.1.1 General
Cast -in-situ piles shall be installed by driving a metal casing with a shoe at the tip and displacing
the material laterally. Driven cast-in -situ pile is formed by driving a casing, permanent or temporary
and subsequently filling the hole with plain or reinforced concrete.
20.1.2 Equipment
The equipment and accessories used for driven cast-in-situ piles shall depend on type of sub-
soil strata, ground water conditions, type of founding material and penetration etc.
Commonly used plants are as per Appendix ‘F’ and few more are given below:
Dolly: A cushion of hardwood or some suitable material placed on the top of the casing to receive the
blows of the hammer
Kentledge: Dead weight used for applying a test load to a pile.
Shoe: Pile Shoe should be of material as specified in the item. The pile shoes may be either cast iron
or mild steel. Cast iron pile shoes shall be made from chill hardened iron as used for making grey
iron casting confirming to IS 210. The chilled iron point shall be free from blow holes and other
surface defects. Cast steel piles shoe shall be of steel conforming to IS 2644. Straps or other fastenings
to cast pile shoes shall be of steel conforming to IS 1079 and shall be cast into the point to form an
integral part of shoe. Different types of pile shoes are shown in Fig. 20.1

Fig. 20.1: Different Types of Pile Shoes
Drop Hammer (or Monkey): Hammer, ram or monkey raised by a winch and allowed to fall under gravity.
Single or Double Acting Hammer: A hammer operated by steam compressed air or internal combustion,
the energy of its blows being derived mainly from source of motive power and not from gravity along.
Pile Frame (or Pile Rig): A movable steel structure for driving piles in the correct position and alignment by
means of a hammer operating in the guides or (leaders) of the frame.
20.1.3 Pile Driving

20.1.3.1 Installation of Piles: Installation of piles shall be as accurate as possible and as per design and
drawings. The verticality or the required batter should be correctly maintained. Particular care shall be taken
in respect of installing either single pile or piles in two pile groups.
20.1.3.2 Deviation /Tolerance

(i) The deviation/tolerance should be as per IS 2911 (Part 1/Sec.1). The piles should not deviate
more than 75 mm or D/4 whichever is less (75 mm or D/10 whichever is more in case of piles
having diameter more than 600 mm) from their designed position at the working level.
(ii) In case of a single pile under a column, the positional deviation should not be more than 50 mm or
D/4 whichever is less (100 mm in case of piles having diameter more than 600 mm. Greater
tolerance may be prescribed for piles driven over water and for raking piles.
20.1.3.3 Sequence of Installation: Normal sequence of installation of pile group is from the centre to the
periphery of the group or from one side to the other. Particular care shall be taken to avoid damaging the
already cast pile while driving a fresh tube nearby before the concrete has sufficiently set. The possibility of
the pile getting damaged is more in compact soils than in loose soils.
20.1.3.4 Driving a Group of Friction Piles

(i) The skin friction increases considerably when the pile bore is driven in the loose sand as the pile
tends to compact the sand. Therefore in such cases the order of installation shall be altered so that
a compact block is not created where driving further pile bore will not be possible. Similar precaution
will have to be taken where stiff clay or compact sand layers will have to be penetrated.
(ii) However driving the pile bore from centre outwards or commencing at a particular selected edge or
even working across the group the problem pointed out in Para (I) above can be avoided.
(iii) In case of very soft soil it is advisable to start driving the bore hole from outside to inside so that the
soil gets restrained from flowing out during operation.

20.1.3.5 Procedure of Pile Driving
(i) Driven cast-in-situ concrete piles are installed by driving a metal casing with a shoe at the
tip/toe and displacing the material laterally.
(ii) These piles may be cast in metal shells which may remain permanently in place or the
casing may be withdrawn which may be termed as uncased driven cast-in-situ cement
concrete piles.
(iii) The metal casing shall be of sufficient thickness and strength to hold in original form and
show no harmful distortion when the adjacent casing is driven and the driving core if any is
withdrawn.
(iv) Driven cast-in-situ concrete piles shall be installed using a properly designed detachable
shoe at the bottom of the casing.
(v) Any liner or bore hole; which is temporarily located and shows partial collapse that would
affect the load carrying capacity of the pile, shall be rejected or repaired as directed by the
Engineer-in-Charge.
20.1.3.6 A proper record of pile driving and other details such as depth driven, sequence of installation
in a group, cut off level/working level shall be mentioned in sequence of occurrence worksheet for
the inspection of Engineer-in-charge.
20.1.4 Jetting
(i) Driving of pile may be assisted by preboring holes or by the use of jets or both subject to
the approval of the Engineer-in-charge. These may be used essentially to achieve the
minimum penetration shown on the drawings where such penetration is not reached under
normal conditions of driving. The diameter of the hole shall; not be greater than the diagonal
dimension of the pile less 100 mm.
(ii) The maximum depth of the preboring shall be such that the specified set (or less) is obtained
when the toe of the pile is at founding level. Preboring shall be as approved by the Engineer-
in-charge and shall not extend beyond one metre above the founding level and the pile
shall be driven to at least one metre below the prebored hole. To ensure that the pile is
properly supported laterally in the hole, any space remaining around the pile at the ground
level after driving is finished shall be backfilled with approved granular material.
(iii) When the water jetting is used at least two jets shall be attached to the pile symmetrically.
The volume and pressure of water at the outlet nozzles shall be sufficient to freely erode
material adjacent to the toe of the pile. The maximum depth of jetting shall be such that the
specified set is obtained when the toe of the pile is at founding level. Jetting shall cease as
directed by the Engineer-in-Charge and shall not proceed beyond one metre above the
founding level and the pile shall be driven at least one metre below the prebored hole.
(iv) To avoid very hard driving and vibration in materials such as sand, jetting of piles by means
of water may be carried out in such a manner as not to impair the bearing capacity of piles
already in place, the stability of the soil or the safety of any adjoining buildings. Details of
arrangement for jetting shall be got approved from the Engineer-in-Charge in advance.
(v) If large quantities of water are used for jetting it may be necessary to make provision for
collection of water when it comes to the ground surface so that the stability of the piling
plant is not endangered by the softening of the ground. Jetting shall be stopped before
completing the driving which shall always be finished by ordinary methods. Jetting shall be
stopped if there is any tendency for the pile tips to be drawn towards the pile already driven
owing to the disturbance to the ground.

20.1.5 Reinforcement
(i) The design of reinforcing cage varies depending upon the driving and installation conditions,
the nature of the sub-soil and the nature of load to be transmitted by the shaft, axial or
otherwise. The minimum area of longitudinal reinforcement of any type or grade within the
pile shaft shall be 0.4 per cent of the sectional area calculated on the basis of the outside
area of the casings of the shaft.
(ii) The curtailment of reinforcement along the depth of the pile, in general, depends on the
type of loading and sub-soil strata. In case of piles subjected to compressive load only, the
designed quantity of reinforcement may be curtailed at appropriate level according to design
requirements. For piles subjected to uplift load, lateral load & moments, separately or with
compressive loads, it may be necessary to provide reinforcement to the full depth of the
pile. In soft clays or loose sands, or where there is likelihood of danger to green concrete
due to driving of adjacent piles, the reinforcement should be provided up to full pile depth,
regardless of whether or not it is required from uplift & lateral load considerations. However,
in all cases, the minimum reinforcement specified in Para (i) above should be provided in
full length of the pile.
(iii) Piles shall always be reinforced with a minimum amount of reinforcement as dowels keeping
the minimum bond length into the pile shaft below its cut-off level, and with adequate projection
into the pile cap, irrespective of design requirements.
Note: In some cases the cage may lift at bottom or at the laps during withdrawal of casing.
This can be minimized by making the reinforcement “U” shaped at the bottom and up to well
secured joints. Also the lifting 5 percent of the length should be considered not to affect the
quality of pile.
(iv) Clear cover to all main reinforcement in pile shaft shall be not less than 50 mm and shall be
maintained by suitable spacers. The laterals of reinforcing cage may be in the form of links
or spirals. The diameter and spacing of the same is chosen to impart adequate rigidity of
the reinforcing cage during the handing and installation. The minimum diameter of links or
spirals shall be 6 mm and the spacing of the links or spirals shall be not less than 150 mm.
The minimum clear distance between two adjacent main reinforcement should normally be
100 mm for full depth of the cage.
(v) The reinforcing cage should be left with adequate protruding length above the cut off level
for proper embedment in the pile cap. Prior to the lowering of reinforcement cage into the
pile shaft, the shaft shall be cleaned of all loose materials.
(vi) Reinforcement in the form of cage shall be assembled with additional support, such as
spreader forks and lacings; necessary to form a rigid cage hoops, links, or helical
reinforcement has to fit closely around the main longitudinal bars and shall be tied by
binding wire of approved quality. The ends of the binding wire shall be turned into the
interior of the pile. Reinforcement shall be placed and maintained in correct position. The
reinforcements shall be joined wherever necessary by welding and the procedure of welding
be followed as described in IS 2751.
20.1.6 Concrete
20.1.6.1 Cement : Cement shall be as specified in agreement item or as specified under sub-head
3.0 of CPWD Specifications. However, high alumina cement shall not be used.
20.1.6.2 Water: Water to be used for concreting shall be as specified under sub-head 3.0 of CPWD
Specifications.
20.1.6.3 Fine Aggregate: Fine aggregate to be used for concreting shall be as specified under sub-
head 3.0 of CPWD Specifications.

20.1.6.4 Coarse Aggregate: For tremie concreting, coarse aggregate having nominal size more
than 20 mm should not be used. Natural rounded shingle of appropriate size may also be used as
coarse aggregate. It helps to give high slump with less water cement ratio.
20.1.6.5 Chemical Admixtures: Admixtures to be used in the concrete shall be as per IS 9103.
20.1.6.6 Concrete Grades to be adopted

(i) Concreting of piles shall be done only with design mix of appropriate grade with weigh
batching of constituents. The grade of concrete to be kept as per nomenclature of the item.
(ii) Only concrete Grade M-25 and/or higher grades shall be used for concreting the piles.
The exact grade of concrete to be used shall mainly depend upon the nature of work and
the general design consideration. However, Concrete Grade M-15 and Grade M-20 shall
not be used for concreting piles under any circumstances, even with weigh batching. The
minimum cement content shall be 400 kg/m3 in all conditions. Even though cement
content can be reduced by use of properly designed mixes or admixtures, but the
cement content should not be less than 350 kg/cum.
(iii) When concreting under water or drilling mud 10 per cent additional cement over the minimum
cement content for the particular grade shall be used.
20.1.6.7 Workability of Concrete: The minimum slump shall be 100 mm when the concrete for the
piles is being vibrated and when the concrete is not vibrated the maximum permitted slump should
be150mm to 180mm at the time of pouring. The degree of workability in both the cases is
considered as very high.
20.1.6.8 Placing of Concrete

(i) Before commencement of pouring of concrete, it shall be ensured that there is no ingress
of water in the casing tubes from bottom. Further, adequate control during withdrawal of
the casing tube is essential so as to maintain sufficient head of concrete inside the casing
tube at all stages of withdrawal.
(ii) Wherever practicable concrete should be placed in a clean dry hole where concrete is
placed in dry hole and when casing is present, the top 3 m pile shall be compacted using
internal vibrators. The concrete should invariably be poured through a tremie, with a funnel
so that the flow is directed and concrete can be deposited in the hole without segregation.
Care shall be taken during concreting to prevent as far as possible the segregation of the
ingredients. The displacement or distortion of reinforcement during concreting and also
while extracting the tube shall be avoided.
(iii) Where the casing is withdrawn from cohesive soils for the formation of cast-in-situ pile, the
concreting should be done with necessary precautions to minimize the softening of the soil
by excess water. Where mud flow conditions exist, the casing of cast-in-situ piles shall not
be allowed to be withdrawn.
(iv) The concrete shall be self compacting and shall not get mixed with soil, excess water, or
other extraneous matter. Special care shall be taken in silt clays and other soils with tendency
to squeeze into newly deposited concrete and cause necking. Sufficient head of green
concrete shall be maintained to prevent inflow of soil or wager into concrete. The placing of
concrete shall be continuous process from the toe level to the top of pile to prevent
segregation, a tube of tremie pipe ass appropriate shall be used to place concrete in all
piles. To ensure compaction by hydraulic static heads, rate of placing concrete in the pile
shaft shall not be less than 6 m (length of pile) per hour.

(v) The diameter of the finished pile shall not be less than specified and a continuous record shall be
kept by the Engineer as to the volume of concrete placed in relation to the length of pile cast. After
each pile has been cast and any empty pile hole remaining shall be protected and back filled as
soon as possible with approved material.
(vi) The minimum embedment of cast-in-situ concrete piles into pile cap shall be 150 mm. Any defective
concrete at the head of the completed pile shall be cut away and made good with new concrete.
The clear cover between the bottom reinforcement in pile cap from top of pile shall not be less than
30 mm. The reinforcement in the pile shall be exposed for full anchorage length to permit it to be
adequately bonded into the pile cap. Exposing such length shall be done carefully to avoid damaging
the rest of the pile. In cases where the pile cap is to be laid on ground a leveling course with cement
concrete of Grade M-15 and of 100 mm thickness shall be provided.
(vii) Normally concreting of piles should be uninterrupted. In exceptional case of interruption of concreting,
but which can be resumed within 1 or 2 hours, the tremie shall not be taken out of the concrete.
Instead it shall be raised and lowered slowly from time to time to prevent the concrete around the
pipe from setting. Concreting should be resumed by introducing a little richer concrete with a slump
of about 200 mm for each displacement of the partly set concrete. If the concreting cannot be
resumed before final set of concrete already laid, the pile so cast may be rejected.
(viii) In case of withdrawal of tremie out of concrete, either accidentally or to removed a choke in the
tremie, the tremie may be re-introduced to prevent impregnation of laitance scum lying on the top of
the concrete already deposited in the bore. The tremie shall be gently lowered on to the old concrete
with very little penetration initially. A vermiculite plug should be introduced in the tremie. Fresh
concrete of slump between 150 mm and 175 mm should be filled in the tremie which will push the
plug forward and swill emerges out of the tremie displacing the laitance/scum. The tremie will be
pushed further in steps masking fresh concrete sweep away laitance scum in its way. When the
tremie is buried by about 60 to 100 cms, concreting may be resumed.
(ix) The top of concrete in a pile shall be brought above the cut-off level to permit removal of all laitance
and weak concrete before capping and to ensure good concrete at the cut-off level for proper
embedment into the pile cap.
(x) Where cut-off level is less than 1.5 metres below the working level concrete shall be cast to a
minimum of 300 mm above cut-off level. For each additional 0.3 m increase in cut-off level below the
working level additional coverage of 50 mm minimum shall be allowed. Higher allowance may be
necessary depending on the length of the pile. When concrete is placed by tremie method concrete
shall be cast to the piling platform level to permit overflow of concrete for visual inspection or to a
minimum of one metre above cut off level. In the circumstances where cut-off level is below ground
water level the need to maintain pressure on the unset concrete equal to or greater than water
pressure should be observed and accordingly length of extra concrete above cut-off level shall be
determined.
20.1.6.9 Placing Concrete under Water

(i) Before concreting under water, the bottom of the hole shall be cleared of drilling mud and all soft
loose materials very carefully. In case a hole is bored with use of drilling mud, concreting should not
be taken up when the specific gravity of bottom slurry is more than 1.2. The drilling mud should be
maintained at 1.5 m above the ground water level. Concreting under water for cast-in-situ concrete
piles may be done either with the use of tremie method or by the use of approved method specialty
designed to permit under water placement of concrete. General requirements and precautions for
concreting under water are as follows:
(a) The concreting of pile must be completed in one continuous operation. Also for bored holes,
the finishing of the bore, cleaning of the bore, lowering of reinforcement cage and concreting
of pile for full length must be accomplished in one continuous operation without any stoppage.
(b) The concrete should be coherent, rich in cement with high slump & restricted water
cement ratio.

(c) The tremie pipe will have to be large enough with due regard to the size of the
aggregate. For 30 mm aggregate the tremie pipe should be of diameter not less
than 150 mm and for larger aggregate, larger diameter of tremie pipe may be
necessary.
(d) The first charge of concrete should be placed with a sliding plug pushed down the
tube ahead of it to prevent mixing of water and concrete.
(e) The tremie pipe should always penetrate well into the concrete with an adequate
margin of safety against accidental withdrawal if the pipe is surged to discharge the
concrete.
(f) The pile should be concentrated wholly by tremie and the method of deposition
should not be changed part way up the pile to prevent the laitance from being
entrapped within the pile.
(g) All tremie tubes should be scrupulously cleaned after use.
When concreting is carried out under water a temporary casing should be installed to the full
depth of the bore hole or 2 m into non collapsible stratum, so that fragments of ground cannot
drop from the sides of the hole into the concrete as it is placed. The temporary casing may
not be required except near the top when concreting under drilling mud.
20.1.7 Testing of Concrete

20.1.7.1 The concrete for the piles shall be sampled in accordance with the norms specified in IS 456.
The frequency of sampling is given in Table 20.1.
TABLE 20.1
3
Quantity of Concrete in the Work m Number of Samples
1-5 1
6-15 2
16-30 3
31-50 4
51 and above 4 plus one additional sample for each additional 50m3 or
part thereof.
Notes:
(i) At least one sample shall be taken from each shift.
(ii) Where concrete is produced as continuous production unit, such as ready mix concrete
plant. The frequency of sampling may be agreed upon mutually by suppliers and purchasers.
20.1.7.2 Test Specimen: Three test specimens shall be made for each sample for testing at 28
days. Additional samples may be required for various purposes such as to determine the strength of
concrete at 7 days or to determine the duration of curing, or check the testing error, additional
sample may also be required for testing samples cured by accelerated methods as described in IS
9103. The specimen shall be tested as described in IS 516.
20.1.7.3 Test Results of Samples: The test results of the samples shall be the average of the
strength of three specimens. The individual variation should not be more than ±15% percent of the
average strength. If the variation is more, the test result of the sample is invalid.

20.1.8 Curing
As per IS 456 – 2000, exposed surfaces of concrete shall be kept continuously in a damp or wet
condition by ponding or by covering with a layer of sacking, canvas, Hessian or similar materials and
kept constantly wet for at least 10 days from the date of placing concrete. The period of curing shall
not be less than 14 days for concrete exposed to dry and hot weather conditions.
20.1.9 Defective Pile

(i) In case defective piles are formed they shall be removed or left in place whichever is
convenient without affecting performance of the adjacent piles or cap as a whole. Additional
piles shall be provided to replace them as directed.
(ii) Any deviation from the designed location alignment or load capacity of any pile shall be
noted and adequate measures taken well before concreting of the pile cap and plinth
beam, if the deviations are beyond permissible limit.
(iii) During chipping of the pile, top manual chipping may be permitted after three days of pile
casting pneumatic tools for chipping shall not be used before seven days after pile casting.
(iv) After concreting the actual quantity of concrete shall be compared with average obtained
from observations actually made in the case of a few piles initially cast. If the actual quantity
is found to be considerably less, special investigations shall be conducted and appropriate
measures taken.
20.1.10 Ready Mix Concrete (RMC)

Alternatively, the contractor can be allowed to use Ready Mix Concrete (RMC) with the permission
of Engineer-in- Charge, provided that the manufacturer assures that for RMC supplied for the
particular work contains the minimum cement content and it is in conformity of approved design mix.
The manufacturer of RMC has also to agree to the sampling and testing procedure as specified
under clause 20.1.7 or alternatively he can propose his own sampling and testing procedure which
should in turn be approved by the Engineer-in -Charge. Normally, RMC supplied to site are mixed
with certain admixtures which enables the concrete to be used within 3 hours of supply at site. In
case RMC supplied is not consumed within 3 hours of supply the quantity of RMC remaining unused
beyond 3 hours shall be rejected and removed from site.
20.1.11 Measurement
Dimension shall be measured nearest to a cm. Measurement of length on completion shall be
along the axis of pile and shall be measured from top of shoe to the bottom of pile cap. No allowance
shall be made for bulking, shrinkage, cut off tolerance, wastage and hiring of tools and equipment for
excavating driving etc.
20.1.12 Rate
The rate includes the cost of materials and labour involved in all the operations described above
including pile embedded in pile cap, except soil investigation, reinforcement, pile cap and grade
beam.
20.2 BORED CAST-IN-SITU REINFORCED CONCRETE PILES

20.2.1 General
The piles are formed within the ground by excavating or boring a pile within it with or without the
use of temporary casing and subsequently filling it with plain or reinforced concrete. When the
casing is left permanently it is termed as cased pile and when the casing is taken out it is termed as
uncased pile.

20.2.2 Equipment
The equipment and accessories used for bored cast-in-situ piles shall depend on subsoil strata, ground
water conditions, type of founding material and penetration etc.
General requirements of boring equipment are as per Appendix ‘D’. The equipment is applicable for bored
piles without the use of bentonite.
20.2.2.1 Boring operation shall be done by rotary percussion type drilling rigs using direct mud circulation or
reverse mud circulation methods to bail out the cuttings or as specified. In soft clays and loose sand, bailer
and chisel method should be used with caution to avoid the effect of suction. Rope operated grabbing tool
Kelly mounted hydraulically operated grab are also used. This method of advancing the hole avoids suction.
The size of cutting tool shall be as per [IS 2911 (Part I Section 2)] and not less than the diameter of pile by
more than 75 mm.
20.2.2.2 Use of drilling mud is stabilizing sides of bore hole where specified shall have properties as defined
in Appendix A.
Permanent casing where specified shall be used to avoid aggressive action of water.
20.2.3 Boring for installing Pile
20.2.3.1 Installation of Piles : As described under clause 20.1.3.1
20.2.3.2 Deviation and Tolerance : As described under clause 20.1.3.2.
20.2.3.3 Procedure of Driving Pile Bore

(i) Bored cast-in-situ concrete piles are installed by making a bore into the ground and removing out
the material.
(ii) The ground shall be roughly leveled and position of pile marked. The boring shall be done with or
without the use of temporary casing. The sides of bore hole; shall be stabilized with the aid of
temporary casing or with the aid of drilling mud of suitable consistency.
(iii) The equipment and accessories shall depend upon the type of bored pile chosen for the job,
consideration of sub-soil strata, ground water condition, type of founding material. Boring operation
normally are done by rotary or percussion type drilling rigs using direct mud circulation on reverse
mud tool shall be as detailed in IS 2911 (Part 1/Sec.2).
(iv) In case permanent/temporary casing is not used then bored pile is stablised with drilling fluid. Bentonite
supplied to site shall conform to IS 2720 (Part V). A certificate shall be obtained by the contractor from
the manufacturer showing properties of each consignment and should be submitted to the Engineer-
in-charge. Bentonite shall be mixed thoroughly with fresh clean water to make a suspension which
will maintain the stability of the pile excavation for the period necessary to place concrete and complete
construction. The temperature of the water used in mixing the bentonite suspension and when supplied
to bore hole shall not be lower than 5ºC. Consistency of the drilling fluid suspension and when
controlled throughout the boring as well as in concreting operations in order to keep the hole stabilized
as well as to avoid concrete getting mixed up with thick suspension of mud.
Frequency and methods of testing drilling fluid shall be as specified and the test results shall be as
specified in IS 2720 (Part V).
(v) Bored cast-in-situ piles in soils which are stable may often be installed with a small casing length
at the top. A minimum of 2.0 m length of top of bore shall; invariably be provided with casing to
ensure against loose soil falling in to drilling mud, or a suitable steel casing. The casing may be left
in place permanently especially in cases where the aggressive action of the ground water is to be
avoided, or in the cases of piles built in water or in cases where significant length of piles could be
exposed due to scour.

(vi) For bored cast-in-situ piles, casing/liner shall be driven open ended with a pile driving
hammer capable of achieving penetration of the liner to the length shown on the drawing or
as directed by the Engineer-in-charge. Materials inside the casing shall be removed
progressively by air lift, grap or percussion equipment or other approved means.
(vii) Where bored cast-in-situ piles are used in soils liable to inflow, the bottom of the casing
shall be kept low enough in advance of the boring tool; to prevent the entry of soil into the
casing, thus presenting the formation of settlements in the adjoining ground. The water
level in the casing should generally be maintained at the natural ground water level for the
same reasons. The joints of the casing shall be made as tight as possible to minimize inflow
of water or leakage of slurry during concreting.
(viii) Boring shall be carried out using rotary or percussion type equipment. Unless otherwise
directed by the Engineer-in-charge the diameter of the bore holes shall be not more than
the inside diameter of the liner.
(ix) After the boring has reached the required depth, the steel reinforcement shall be lowered
in position maintaining the specified size of cover on all sides. The bore shall then be
flushed with bentonite slurry and concreting shall be taken up exactly as described under
clause 20.1.6.8.
20.2.3.4 A proper record of pile driving and other details such as sequence of installation of piles,
dimension of piles, depth bored, time taken for concreting etc. shall be maintained in sequence of
occurrence at site as per clause 20.1.3.6.
While drilling mud is used, the specific gravity of fresh supply and contaminated mud in the hole
before concreting is taken up shall be recorded for first ten piles and subsequently at interval of 10
piles or as specified.
As specified under clause 20.1.5.
20.2.5 Concrete
20.2.6 Ready Mix Concrete

20.2.7 Measurement
Dimensions shall be measured nearest to a cm. Measurement of length on completion shall be
along the axis of pile and shall be measured up to the bottom of pile cap. No allowance shall be made
for bulking, shrinkage, cut off tolerance, wastage and hiring of tools, equipment for excavating,
driving etc.
20.2.8 Rate
The rate includes the cost of material and labour involved in all the operations described above
including pile embedded in pile cap except reinforcement, pile cap and grade beam.
20.3 UNDER-REAMED RCC PILES

20.3.1 General
(i) Under-reamed piles are bored cast-in-situ and bored compaction concrete types having
one or more bulbs formed by suitably enlarging the bore hole for the pile stem. With the
provision of bulb(s) substantial bearing or anchorage is available.

(ii) These piles find application in widely varying situations in different types of soils where
foundation are required to be taken down to a certain depth in view of considerations like
the following requirements :
(a) To avoid the undesirable effect of seasonal moisture changes as in expansive soils.
(b) To reach firm strata.
(c) To obtain adequate capacity for downward, upward and lateral loads and moments
(d) To take foundations below scour level.
(iii) When the ground consists of expansive soil e.g. black cotton soil, the bulb of the under
ream pile provides anchorage against uplift due to swelling pressure apart from the increased
bearing capacity.
(iv) In case of filled up or otherwise weak strata overlying the firm strata, enlarged base in the
form of under-reamed bulb in firm strata provides larger bearing area and piles of greater
bearing capacity can be made.
(v) In loose to medium pervious sandy silty strata, bored compaction piles can be used as the
process of compaction increases the loads bearing capacity of the piles.
(vi) Under- reamed piles may also be used under situations where the vibration and noise
caused during construction of piles are to be avoided. The provision of bulb(s) is of special
advantage in under reamed piles to resist uplift and they can be used as anchors.
20.3.2 Pile Grouping

(i) For bored cast in situ under-reamed piles at usual spacing of 2 Du (DU is bulb diameter),
the group capacity will be equal to the safe load of individual pile multiplied by the number
of piles in the group. For piles at spacing of 1.5 Du the safe load assigned per pile in a
group should be reduced by 10 per cent.
(ii) In under-reamed compaction piles, at the usual spacing of 1.5 Du, the group capacity will
be equal to the safe load on individual pile multiplied by the number of piles in the group.
Note: In order-reamed compaction piles, the capacity of the group may be more than
given in Para (i) above on account of compaction effect.
(iii) In non-expansive soils, when the cap of the pile group is cast directly on a reasonably firm
stratum it may additionally contribute towards the bearing capacity of the group.
(iv) In load bearing walls piles should generally be provided under all wall junctions to avoid
point loads on beams. Position of intermediate piles is then decided by keeping door openings
fall in between two piles as far as possible.
20.3.3 Equipment and Other Accessories

(i) The selection of equipment and accessories will depend upon the type of under-reamed
piles, site conditions and nature of strata. Also it will depend on economic considerations
and availability of manually or power operated equipment.
(ii) A typical list of equipment for manual construction is given in Appendix B.
(iii) Bore holes may be may be made by earth augers. In case of manual boring, an auger
boring guide shall be used to keep bores vertical or to desired inclination and in position.
After the bore is made to the required depth, enlarging of the base shall be carried out by
means of an under-reaming tool.
(iv) In ground with higher water table having unstable pile bores, boring and under-reaming may
be carried out using suitable drilling mud. General guidelines for bentonite drilling mud are
given in Appendix ‘A’. In normally met soil strata, drilling mud can be poured from top while
boring and under-reaming can be done by normal spiral earth auger and under-reamer.

(v) The level of drilling mud should always be about one meter above water table or the level
at which caving-in occurs. In case of very unstable strata with excessive caving-in continuous
circulation of drilling mud using suitable pumping equipment and tripod, etc along with
modified auger and under-reamer may be used.
(vi) Some times permeable strata overlying a rim clayey stratum may be cased and normal
boring and under-reaming operation may be carried out in clayey stratum.
(vii) To avoid irregular shape and widening of bore hole in very loose strata at top a casing pipe
of suitable length may be used temporarily during boring and concreting.
(viii) For improved control over the inclination of batter/raker piles a tripod hoist with fixed pulley
should be used for lowering in of under-reaming tools.
(ix) For placing concrete in bore holes full of drilling mud or sub-soil water tremie pipe of not
less than 150 mm diameter with flap valve at the bottom should be used.
(x) For batter/raked under-reamed piles the reinforcement cage should be placed guiding it
by a chute or any other suitable method. If concreting is not done by tremie, it should be
done by chute.
(xi) In under-reamed compaction piles, suitable device should be used for guiding the movement
of drop weight and specified core assembly for its vertical driving for operating the drop
weight and specified core assembly for its vertical driving for operating the drop weights of
adequate capacity, suitable winch with hoisting attachment should be used.
20.3.4 Pile Boring

(i) Under-reamed piles may be constructed by selecting suitable installation techniques at
given site depending on sub-soil strata conditions and type of under-reamed piles and
number of bulbs.
(ii) In construction with equipment suggested under Appendix ‘B’ initially boring guide is fixed
with its lower frame leveled for making desired angular adjustment for piles at batter/rake.
Boring is done up to required depth and under-reaming is completed.
(iii) In order to achieve proper under-reamed bulb, the depth of bore hole should be checked
before starting under reaming. It should also be checked during under-reaming and any
extra soil at the bottom of bore hole; removed by auger before reinserting the under-
reaming tool.
(iv) The completion of desired under-reamed bulb is ascertained by
(a) The vertical movement of the handle and
(b) When no further soil is cut.
(v) In double or multi under-reamed piles, boring is fist completed to the depth to the first (top)
under-ream only and after completing the under-reaming boring is extended further for the
second under-ream and the process is repeated.
20.3.4.1 Control of Alignment

(i) The piles shall be installed as correctly as possible at the correct location and truly vertical
(or at the specified batter/inclination). Great care shall be exercised in respect of single pile
or piles in two pile groups under a column.
(ii) As a guide for vertical piles a deviation of 1.5 per cent and for raker piles a deviation of four
percent shall not normally be exceeded. In special cases, a closer tolerance may be
necessary.

(iii) Piles shall not deviate more than 75 mm or one quarter the stem diameter, whichever is
less (75 mm or D/10 whichever is more in case of piles having diameter more than 600 mm)
from the designed position at the working level.
(iv) In case of single pile under a column the positional deviation should not be more than 50
mm or one quarter of the stem diameter whichever is less (100 mm in case of piles having
diameter more than 600 mm).
(v) For piles where cut-off is at substantial depths, the design should provide for worst
combination of the above tolerances in position and inclination.
(vi) In case of piles deviating beyond these limits corrective measures where necessary may be
taken in the form of increasing pile size, provision of extras reinforcement in the pile, redesign
of pile cap and pile ties. If the resulting eccentricity cannot be taken care of by the above
measures, the piles should be replaced or supplemented by; one more additional piles.
20.3.5 Reinforcement in Piles

(i) The provision of reinforcement will depend on nature and magnitude of loads, nature of
strata and method of installation. It should be adequate for vertical loads, lateral load and
moments acting individually or in combination. It may be curtailed at appropriate depths
only under the advice of the structural engineer. However, provision of reinforcement shall
be as specified in drawing.
(ii) The minimum area of longitudinal reinforcement (any type or grade) within the pile shaft
should be 0.4 per cent of the sectional area calculated on the basis of outside area of shaft
or casing if used.
(iii) Reinforcement is to be provided in the full length irrespective of any other considerations
and is further subject to condition that a minimum number of three 10 mm dia mild steel or
three 8 mm dia high strength steel bars shall be provided. The transverse reinforcement as
circular stirrups shall not be less than 6 mm dia. Mild steel bars at a spacing of not more
than the stem diameter or 30 cm, whichever is less.
(iv) For under reamed compaction piles, a minimum number of four 12 mm diameter mild steel
or four 10 mm diameter high strength steel bars shall be provided.
(v) For piles of lengths exceeding 5 m and or 37.5 cm diameter, a minimum number of six 12
mm diameter HSD bars shall be provided.
(vi) For piles exceeding 40 cm diameter a minimum number of six 12 mm diameter high strength
steel bars shall be provided.
(vii) The circular stirrups for piles of length exceeding 5 m and diameter exceeding 37.5 cm
shall be bars of 8 mm diameter.
(viii) For piles subject to uplift loads, adequate reinforcement shall be provided to take full up lift
which shall not be curtailed at any stage.
(ix) For piles up to 30 cm diameter, if concreting is done by tremie, equivalent amount of steel
placed centrally, may be provided at sides.
(x) The minimum clear cover over longitudinal reinforcement shall be 50 mm. In aggressive
environment of sulphates etc. it may be increased to 75 mm.
20.3.6 Concrete
20.3.6.1 Materials : Cement, water, fine aggregate, coarse aggregate and chemical admixtures etc.
as described under clause 20.1.6.

20.3.6.2 Concrete grades to be adopted : Same as described under clause 20.1.6.6.
20.3.6.3 Workability of Concrete : Same as described under clause 20.1.6.7.
20.3.6.4 Placing of Concrete

(i) Same as Para (i) to (x) under clause 20.1.6.8.
(ii) Concreting shall be done as soon as possible after completing the pile bore. The bore hole full of
drilling mud should not be left un-concreted for more than 12 to 24 hours depending upon the
stability of the bore hole.
(iii) For placing concrete in pile bores, a funnel should be used and method of concreting should be
such the entire volume of the pile before is filled up without formation of voids and/or mixing of soil
and drilling fluid in concrete.
(iv) In empty bore holes for under-reamed piles a small quantity of concrete is poured to give about 100
mm layer of concrete at bottom. Reinforcement is lowered next and positioned correctly. Then
concrete is poured to fill the bore hole. Care should be taken that soil is not scrapped from side if
rodding is done for compaction. Vibrators shall not be used.
(v) If water is confined up to the bucket length portion at the toe & seepage is low, the water should be
bailed out and concreting should be done as prescribed in Para (iv) above.
(vi) In case the pile bore is stabilized with drilling mud or by maintaining water head within the bore
hole, the bottom of bore hole shall be carefully cleaned by flushing it with fresh drilling mud and pile
bore will be checked for its depth immediately before concreting.
(vii) Concreting shall be done by tremie method. The tremie should have a valve at bottom and lowered
with valve closed at the start and filled up with concrete. The valve is then opened so permit the flow
of concrete which permits upward displacement of drilling mud.
(viii) The pouring should be continuous and tremie is gradually lifted up such that the tremie pipe opening
remains always in the concrete. At the final stage the quantity of concrete in tremie should be
enough so that on final withdrawal some concrete spills over the ground.
Note: (1) The concrete should be coherent, rich in cement (not less than 350 kg/m3) and
slump not less than 150 mm.
(2) The tremie pipe should always penetrate well into the concrete with an adequate
margin of safety against accidental withdrawal if the pipe is surged to discharge
the concrete.
(ix) In inclined piles, concreting should be done through a chute or by tremie method.
(x) For under-reamed bored compaction piles, the pile bore is first filled up without placing any
reinforcement. Concreting is done as prescribed in paras (iv) depending upon the situation. Soon
after the specified core assembly shall be driven and extra concrete shall be poured in simultaneously
to keep the concrete up to ground level. If hollow driving pipe is used in core assembly the pipe shall
be withdrawn after filling it with fresh concrete which will be left behind.
20.3.6.5 Estimation of Concrete Quantity

(i) The extra quantity required for each bored cast-in-situ under-reamed bulb of 2.5 times the stem diameter
may be taken equal to a stem length of 4 to 4.5 times its diameter, depending upon the nature of strata and
other site conditions. The volume of concrete actually placed shall be observed in the case of quantities of
the concrete and cement for the subsequent piles.
(ii) For under-reamed compaction piles the amount of concrete used is about 1.2 times of the under-
reamed cast-in-situ piles.
Note: If the estimates of concrete consumption are on the volume of the bore holes and not on the
basis of concrete quantity actually consumed, the concrete used may be found lesser than estimated
and cement consumption may work out to be less.

20.3.6.6 Placing Concrete under Water : As described under clause 20.1.6.9.
20.3.6.7 Testing Works Concrete : As described under clause 20.1.7.
20.3.6.8 Curing : As described under clause 20.1.8.
20.3.6.9 Ready Mix Concrete (RMC) : As described under clause 20.1.10.
20.3.7 Pile Cap (Fig. 20.2 and 20.3)

(i) Pipe cap are generally designed considering pile reaction as either concentrated loads or
distributed loads. The depth of pile cap should be adequate for the shear, diagonal tension
and it should also provide the necessary anchorage of reinforcement both for the column
and the pile.
(ii) The pile caps may be designed by assuming that the load from column or pedestal is
dispersed at 45º from the top of the cap up to the mid depth of the pile cap from the based
of the column or pedestal. The reaction from piles may also to be taken to be distributed at
45º from the edge of the pile, up to the mid depth of the pile cap on this basis, the maximum
bending moment and shear forces should be worked out at critical sections.
(iii) Full dimension of the cap shall be taken as width to analyse the section for bending and
shear in respective direction. Method of analysis and allowable stresses may be according
to IS 456.
(iv) The clear overhang of the pile cap beyond the outermost pile in the group shall normally be
100 to 150 mm depending upon the size of the pile.
(v) The cap is generally cast over a 75 mm thick leveling course of concrete. The clear cover
for the main reinforcement of cap slab shall be not less than 75 mm.
(vi) The pile should project 50 mm into the cap concrete. The design of grade beams if used
shall be as given in IS 2911 (Part III).
Fig. 20.2 : Pedestal Piles

Fig. 20.3 : Cap for Two Piles (Typical)
20.3.8 Grade Beams

(i) The grade beams supporting the walls; shall be designed taking due account of arching
effect due masonry above beam. The beam with masonry due to composite action behaves
as a deep beam.
(ii) The minimum overall depth of grade beams shall be 150 mm. The reinforcement at bottom
should be kept continuous in all the beams and an equal amount may be provided at top to
a distance of quart span both ways from the pile centre.
(iii) The longitudinal reinforcement both at bottom and top should not be less than three bars
of 10 m diameter mild steel (or equivalent deformed steel).
(iv) Stirrups of 6 mm diameter bars should be at 300 mm spacing which should be reduced to
100 m at the door openings near the wall edge to a distance of three times he depth of
beam. No shear connectors are necessary in wall.
(v) In expansive soil the grade beam shall be kept a minimum of 80 mm clear off the ground. In
other soils, the beams may rest on ground over a leveling concrete course of about 80 mm
as shown. In this case part load may be considered to be borne by ground and it may be
accounted for; in the design of piles. However, the beams should be designed as usual.
(vi) In case of exterior beams over piles in expansive soils a ledge projection of 75 mm thickness
an extending 80 mm into ground as shown shall be provided on outer side beam. Typical
sections of internal and external beams are shown below.

20.4 DRIVEN PRECAST R.C.C. PILES
20.4.1 General
Driven Precast Concrete Pile is a pile constructed in a casting yard and subsequently driven in
the ground with or without jetting, or other technique like preboring (depending on the conditions of
soil) when the pile has attained sufficient strength. By driving, the subsoil is displaced and remain in
direct contact with the pile. These piles find wide application particularly for structures such as wharves,
etc. to act as a free standing pile above the soil/water level or where conditions are unfavorable for
use of cast-in-situ piles.
(i) The longitudinal reinforcement of specified grade and size shall be provided in the pre-cast
concrete piles, for the entire length. All the longitudinal bars shall be of same length and
should fit tightly in the pile shoe if the same is provided.
(ii) Extra bars for supporting the longitudinal steel shall be provided, to resist the local bending
moments but the same should be detailed in the drawings prominently so that the sudden
discontinuity can be avoided. The non provision of the extra bars may lead to cracks in the
pile during heavy driving.
(iii) As per IS 2911 (Part1/Sec.3) the area of main longitudinal reinforcement shall not be less
than the percentages of cross sectional area of the piles as detailed below:
(a) Piles with a length 30 times the least dimension: 1.25 per cent
(b) Piles with a length 30 to 40 times the least dimension: 1.5 per cent
(c) Piles with a length more than 40 times the least dimension: 2 per cent
(iv) The lateral reinforcements, which are normally in the form of links or spirals of not less
than 8mm diameter TMT bars, has its own particular importance in resisting the driving
stresses induced in the pile. The volume of lateral reinforcement shall not be less than the
following:
(a) At both ends of the pile for a distance of 3 times the least width – not less than 0.6 per
cent of the gross volume of pile.
(b) At central portions of the pile – not less than 0.2 per cent of the gross volume of pile.
(v) The spacing of the lateral ties in a pile shall be so arranged that the concrete should have
free flow around the reinforcements. The gradual transition of close spacing of lateral
reinforcements near the ends to the increased spacing in the central portions of the piles
should be accommodated by gradually increasing the spacing of the ties in a length of 3
times the least width of the pile.

(vi) The cover to reinforcement should be provided to longitudinal bars. In normal conditions
the cover thickness to be provided is 50 mm and in case the piles are exposed to sea water
or water having other corrosive contents the minimum thickness of cover shall be 75 mm.
Note: Where the concrete of pile is liable to attack of sulphates, chlorides present in ground
water a minimum cover thickness of 75 mm shall be provided. In addition, the piles may be
coated with some suitable material.
(vii) Each longitudinal bar shall be in one length as far as possible, also preferably the full
length bar shall be used. However, in unavoidable cases if the bars are to be joined, they
shall be done by butt welding duly staggering the joints.
(viii) The hoops or links that are to be tied to longitudinal reinforcement shall be tied with the
specified type of binding wire and the free ends of the wire shall be turned into the interior
of the pile.
(ix) Preferably the hoop or link reinforcement shall be welded to the longitudinal bars so as to
achieve a tight fitting.
(x) Temporary or permanent spreader forks spaced at 1.5 m shall be used to keep the
longitudinal bar in proper position and spacing.
(xi) Before concreting, the reinforcements shall be checked by Engineer-in-charge who shall
ensure that the reinforcements are tied as per approved design and drawing and shall
ascertain that the tying is perfect.
20.4.3 Equipment and Ancillaries

(i) The selection of equipment mostly depends upon the hardness of the strata. For deriving the
size and weight of the pile to be handled, the most important point is the location of work.
(ii) Generally, the following equipments are necessary for the installation of piles:
(a) Movable steel or timber structure duly designed to handle the pitching and driving
the piles to the correct position and alignment.
(b) Tackles to handle piles from casting/stacking yard.
(c) To prevent the head of the pile from being damaged during drilling operation and to
distribute the blow over the cross section of the head of the pile. A temporary steel
driving cap, normally termed as ‘Drive cap’ is placed on the top of the pile.
(d) A pad, block or packing of hard wood or some suitable resilient material normally
termed as “Dolly” is fixed to the upper portion of he cap (helmet) for preventing the
shock from hammer on the head of the pile.
(e) A single acting” or “double acting” hammer is used depending on whether the hammer
is allowed to fall under gravity along or is operated with the source of motive power to
derive the energy.
(f) Sometimes it so happens that he piles are to be driven below the pile frame leaders,
with the result the hammer may not be in a position to reach the pile. Under such
circumstances a removable extension piece known as “follower” or “long dolly” is
used to transmit the hammer blows over the pile head.
(g) When a particular type of soil strata is met with, the driving conditions may require
equipments for jetting/pre-boring for installation of piles.
(h) When the piles are to be driven in rock, coarse gravel, clay with cobbles, or other
soils, which may damage the tip of the pile, flat or coaxial shoes made out of steel or
cast iron shall be provided at the tip of the pile.

(i) While driving a pile in a uniform clayey soil or sandy soil no advantage can be derived
by tapering the tip of the pile hence no shoe need be provided for the tip of the pile
while driving piles in such soils.
(j) When jetting is to be undertaken a jet tube may be cast into the pile by connecting
the same to the pile shoe which is normally provided with jet holes. It is not advisable
to provide a central which is likely to be choked.
(k) The best results can be achieved by providing four holes in four directions. However,
providing two holes in opposite direction may also serve the purpose.
(l) Alternatively, two or more jet pies may be attached to the sides of the pile. The pile
may get off loaded if proper balanced arrangement of jet is not made.
20.4.4 Concrete
20.4.4.1 Materials: Cement, water, fine and coarse aggregate, chemical admixtures etc. As described
under clauses 20.1.6.
20.4.4.2 Concrete Grades to be Adopted: Same as described under clause 20.1.6.6
20.4.4.3 Workability of Concrete: The degree of workability in this case is “low” as the concrete is
placed where the section is not heavily reinforced, also the concrete in the pile is vibrated with both
internal as well as external vibrators, and therefore minimum slump should be 25 mm to 50 mm.
20.4.4.4 Form-Work/Mould
(i) Only steel moulds manufactured out of sturdy steel sections and sheets to cast the required
size of the pile are to be used. Timber moulds shall not be permitted, under any
circumstances.
(ii) The mould shall sustain the stresses generated due to the use of immersion/plate vibrators
and some time even form vibrator, depending upon the size and strength of the pile to be
cast.
(ii) The manufacturing of the mould shall be so simple that the sides could be opened within 16
to 24 hours of casting by simply loosening the bolts without damaging the edges of the pile.
(iv) Fixing supports for the sides of the mould shall be done from outside and no use of through
bolts through the concrete shall be permitted to support the opposite sides of the mould.
(v) Proper mechanism shall be introduced to fix the sides to the top of the casting platform so
that the plate from vibrators can be operated without disturbing the mould.
(vi) In case of square piles provision for forming champhers of the pile for the corners shall be
made in the mould itself.
(vii) The mould should be such that when the pile is demoulded all the surfaces of the pile
except the side from which the concrete is laid should get form finish. No rendering or
finishing shall be permitted on any surface of the concrete after demoulding.
(viii) Piles whose surfaces are plastered or rendered, edges repaired etc. shall be rejected and
removed from site.
(ix) After every casting, when the sides of the mould are opened the same shall be cleaned
nicely and form oil manufactured by reputed company shall be applied over the surface
before the mould is adjusted for filling the concrete, for next pile. The normal practice of
applying grease mixed with diesel or waste oil instead of the form-oil shall not be permitted.

20.4.5 Casting Concrete Piles (Pre-casting)
(i) The casting yard shall be so constructed that the piles that are cast can be lifted directly
from their beds and transported to the storing yard with minimum handling and avoiding
any damage to the pile.
(ii) The casting yard shall have well drained surface so that the water used for curing the
already cast piles do not accumulate on the yard inconveniencing the working on subsequent
piles.
(iii) The size of the casting platform shall be large enough to accommodate the minimum number
of piles to be cast for full 11 days depending upon the proposed progress of work per day,
as a pile once cast cannot be lifted from the casting bed till the expiry of ten days, therefore
no piles can be cast on these spaces till the piles more than 10 days old are shifted.
(iv) The casting yard shall be well covered not only from top but also from sides to avoid the
direct sun-rays falling on the piles that are under set. The pile should also be protected
from rain and wind.
(v) Before taking up actual concreting, the moulds to be concreted for full days work shall be
fixed in position and preferably moulds for concreting on the subsequent day shall also be
kept ready in advance.
(vi) If the contractor is permitted to start concrete with lesser number of moulds than that can
be cast within a day, the action will prompt the contractor to open the sides of moulds
already cast prematurely to continue concreting for the full day, which is not desirable as
the quality of the concrete will be hampered.
(vii) The inner faces of the mould shall be cleaned; form-oil of approved brand and manufacture
shall be applied.
(viii) The reinforcements shall be lowered carefully in the mould and fixed in position with proper
cover blocks and spacers on all surfaces.
(ix) On getting formal approval of the Engineer-in-charge for the fixing of form-work in position
and on getting the pre-measurements of the reinforcements recorded, concreting with
specified grade shall be taken up. The slump should be checked frequently and constant
w/c ratio shall be maintained.
(x) The piles should be cast from end to end, using immersion, form vibrators, avoiding over
vibration. Proper care should be taken to see that the concrete is packed in the mould and
consolidated. When the mould is full the top surface of concrete shall be neatly toweled
and finished smooth.
(xi) Proper precaution shall be taken to ensure that the vibration from the adjoining work does
not affect the previously placed concrete for piles during setting period.
(xii) On completing the concreting for a particular pile the following information shall be engraved
(not painted) on each pile.
(1) Date of casting.
(2) Grade of concrete used.
(3) No. of lot.
The lot No. will help to locate the exact position where the particular pile has to be used.
20.4.6 Testing Works Complete

As prescribed under clause 20.1.7.

20.4.7 Ready Mix Concrete
As prsescribed under clause 20.1.10.
20.4.8 Curing
(i) Provision for curing as given under clause 20.1.8 shall be followed in addition.
(ii) The piles shall not be lifted from the casting bed for a minimum period of 10 days from the
date of casting.
(iii) When the piles are shifted to stacking yard after the expiry of ten days, where the piles will
have to be kept for a period of 28 days from the date of casting, the piles in stacks shall be
covered with sacks so that the piles do not come in contact with sun rays till they attain full
strength.
(iv) Lastly, the most important factors affecting the time of curing are the method of curing,
weather during hardening, probable hardness of driving and the method of lifting and
pitching.
(v) The Engineer-in-charge may fix up the exact period of curing for a particular project
considering all the factors mentioned in Para (iv) above.
20.4.9 Storing and Handling

(i) After the expiry of 10 days from the date of casting, the piles are to be removed from the
casting bed and shifted to the stacking yard where the piles shall be kept for a further
period of 18 days i.e. 28 days after casting and later till they are carried for driving.
(ii) The piles shall be stored on a firm ground which will not liable for unequal subsidence or
settlement under the weight of the stack of piles.
(iii) Timber sections of suitable size shall be placed over the level ground to stack the piles on
top. The spacing between the timber sections shall be so adjusted that the piles are not
subjected to undue bending stresses, while in stack.
(iv) Spaces shall be left around the piles in the stack so that they can be lifted without difficulty
and necessary piles can be cured beyond 10 days.
(v) The order of stacking the piles shall be such that the older piles can be withdrawn without
disturbing the newly placed piles. Separate stacks shall be provided for the piles of different
lengths.
(vi) If ordered by the Engineer-in-Charge or if weather conditions so require arrangements for
curing the piles for further period shall be made when the piles are stored in the stack.
(vii) Care shall be taken to see that the piles are not damaged or cracked at the time of lifting,
handling transportation, etc.
(viii) While transporting the piles from the stocking yard to the site, the piles shall be supported
at approximate lifting holes provided for the purpose. In case during transportation if the
piles are to be unloaded temporarily they shall be placed on trestles or blocks located at
the lifting points.
20.4.10 Driving Piles

(i) Though from the consideration of maintaining the time schedule and economy in
construction, the pre-cast concrete piles have to be driven without any possible delay, still
it shall be kept in mind that the piles chosen for driving should be thoroughly cured and are
sufficiently hard. To achieve this proper schedule shall be followed, in the operations of
casting, curing, stacking and transportation of piles to site.

(ii) The heads of the pre-cast concrete piles to be driven shall be protected with packing of resilient
material against the possible damage due to the use of heavy hammers. Care shall be taken to
see that packing is evenly spread and placed securely. On top of the packing a helmet should be
placed and provided with a dolly of hardwood or any suitable material not thickens than the width
of the pile.
(iii) The failure in the pile may occur by compression or tension when the blow of the hammer generates
the stress waves which traverses the length of the pile. Failure due to compressive stresses mostly
occurs at the heads. Head stresses are independent of ground conditions and mainly depend upon
the weight of the hammer, its drop and the stiffness of the head cushion.
(iv) By using heaviest hammer and softest packing the maximum set for a given stress is obtained. The
drop of the hammer however should; be adjusted to suit the allowable stress in the concrete.
(v) Optimum driving conditions can be maintained only by regular replacement of packing materials
as prescribed in Para (ii) above, since the stiffness in head packing materials increases with
repeated use.
(vi) Only in cases of exceptionally hard driving, where theoretically the compressive stresses of toe can
reach twice the head stresses, failure in lower portions of the pile can occur. In practice, however,
this rarely occurs as the compressive stresses to a great extent tend to be uniform over the
considerable length of the pile.
(vii) Due to reflection of compressive wave to “free end”, the longitudinal tension is caused in the pile.
This situation arises at a time when the ground resistance is low and/or when the hammer rebounds
due to head conditions mainly because of the use of hard packing and light hammer. In addition, an
unsupported long pile negotiating a hard stratum will be subjected to transverse or flexural vibrations
in the pile in case the blow from the hammer becomes non-axial or if the pile is not restrained to
reduce the effect of a long pile.
(viii) For driving a pile; any type of hammer can be used provided the pile penetrates to the prescribed
depth or attain the specific resistance without getting damaged.
(ix) The hammer, helmets, dolly and the pile below should be co-axial and should sit perfectly one over
the other. However, the heaviest possible hammer should preferably be used and the stroke should
be so managed so as not to damage the pile.
(x) The choice of hammer mainly depends upon whether the pile is to be driven to a given resistance or
to a given depth.
(xi) Normally, for a single acting or a drop hammer the stroke should be limited to 1.2 m but 1.0 m is
preferable. Shorter stroke may be used in cases where there is a danger of damaging the pile, a few
examples of which are described below:
(a) Hard surface has to be penetrated in the early stages when a long pile has to be driven.
(b) When there is a soft ground up to a considerable depth, a large penetration is achieved at
each blow.
(c) The pile suddenly reaches refusal when it meets with rock or other virtually impenetrable soil.
(xii) If a satisfactory set is achieved for ten consecutive blows with an appropriate hammer and drop the
method of driving should be repeated with caution and long continued driving. However, after the pile
has almost ceased to penetrate the driving should be stopped especially when the hammer with
moderate weight is used.
(xiii) Sometimes it so happens that the rate of penetration suddenly changes without any satisfactory
reasoning or soil conditions. Under such circumstances the pile driving should not be continued till
real problem is investigated and remedy thought over.

20.4.10.1 Jetting with Driving Pile
(i) The jetting operation is effective only in the cohesion less soils such as sand, gravel and fine
grained soils with very less percentage of clay. The jetting will be ineffective in clay soils.
(ii) The main purpose of jetting is to minimize or almost eliminate the resistance at the toe and
last the same time the frictional resistance along the surface of the pile shaft also gets
reduced.
(iii) Very hard driving and vibrations can be avoided when the toe resistance is eliminated and
also the rate of penetration is increased considerably when compared to the normal driving
methods without jetting.
(iv) Jetting operations shall be carried out only when specifically ordered by the Engineer-in-
Charge. Jetting shall be carried in a manner that the stability of soil and the bearing capacity
of piles already driven is not in any way impaired. Similarly, the safety of the adjoining
structures shall be taken into consideration.
(v) For effective jetting the quantity of water required is directly related to the cross sectional
area of the piles (including external jet pipes). In dense cohesion less soils the quantity of
water up to 2 litres per minutes per sq.cm. of pile cross section may be required. Less
quantity of water may be needed in loosely compacted soils.
(vi) The water pressure to be maintained is between 5.6 kgf/cm2 to 10.6 kgf/cm2 or more. In
case large quantities of water are used the draining arrangement for the water that emerges
on the ground shall have to be made otherwise the stagnant water may soften the ground
endangering the piling equipment resting above.
(vii) To minimize the risk of blockages, the nozzle should not be positioned at the point of the
toe. The arrangement of jets should be balanced to ascertain the penetration of the pile
vertically. It is advisable to surge down an independent pile or two pipes may be attached to
the opposite sides of the pile for effective jetting operation.
(viii) The pile shall be allowed to enter the ground gradually after operating the water under the
weight of pile and the hammer. Acceptable verticality may be achieved by use of rigid
leaders, duly controlling the rate of penetration with a pile winch.
(ix) On achieving maximum apparent penetration with light driving by the method prescribed
above and when the water jets are running the further penetration may be attained in the
cohesion less soils. The piles shall be driven to the final position or set when the jetting is
complete.
(x) Before closing the driving operation, the jetting should be stopped and the driving shall be
continued by ordinary driving methods. If due to the ground disturbances, the pile tips tend
to be drawn towards the piles already driven, jetting should be stopped immediately.
(xi) The correct working of jets should be tested before the work on driving the pile is commenced.
If the pile is not provided with as “built in jet arrangement” independent jet pipes down the
outside the pile can be used and to achieve the best result jets working on several faces of
the pile can be practical which will also assist maintaining the verticality.
20.4.10.2 Stripping Pile Heads

(i) Stripping of pile shall be done in such a manner that a minimum 50 mm length of pile
projects into the pile cap. Sufficient length of reinforcement from the pile shall be exposed
for embedding the same inside the pile cap.
(ii) The stripping operation or exposing the reinforcement of the pile shall be done very carefully
without damaging the pile proper. In case any portion of the concrete cracks, the defective
portion shall be cut and the portion repaired with new concrete joining properly with old
concrete.

20.4.10.3 Lengthening Piles
(i) Sometimes the length of a pile has to be increased either before or during driving; this can
be done by casing additional concrete over the old pile. In such cases the original head of
the pile is cut to expose minimum 200 mm length of bar.
(ii) The exposed steel should be cleaned properly and shall be held in firm position, while full
penetration butt welding is done.
(iii) In case the conditions on site are not favorable to attempt butt welding, a minimum length of
40 d (40 times the diameter of main bar) of the original pile shall be exposed and the new
steel should be overlapped over the exposed steel. The overlap shall be spot welded.
(iv) On completion of welding/overlapping the reinforcement and tying the spirals, for the
extended length of reinforcements the extras portion of the pile can be concreted thus
extending the original pile.
20.4.11 Risen Piles

(i) Sometimes due to ground heave there is a possibility that piles already driven to the final
depth may start rising when adjacent piles are being driven; such rising shall be noted at
frequent intervals till driving on adjacent piles is in progress.
(ii) On completion of driving the adjacent piles, the piles that are risen shall again be driven
back either to their original level or up to a point of resistance.
20.4.12 Pile Cap

As per clause 20.3.7.
20.4.13 Grade Beam

As per clause 20.3.8.
20.4.14 Measurement
Dimension shall be measured nearest to a cm. Measurement of length on completion shall be
along the axis of pile and shall be measured from top of shoe to the bottom of pile cap No allowance
shall be made for bulking, shrinkage, cut off tolerance, wastage and hiring of tools, equipment for
excavating and driving etc.
20.4.15 Rate
The rate includes the cost of materials and labour involved in all the operations described above
including pile embedded in pile cap, centering, shuttering except reinforcement, pile cap and grade
beam.
20.5 LOAD TEST ON PILES

20.5.1 General
The bearing capacity of a single or group of piles shall be determined from test loading. It is most
direct method for determining safe load on pile and it is more reliable on account of its being in-situ
test. The load test on a concrete pile shall not be carried out earlier than 28 days of its casting. Initial
test shall be carried on test pile which is not used as working pile and Routine tests shall be carried
out as a check on working pile. Routine test shall be one-half percent to two percent of total number
of piles or as specified, applicable to vertical and lateral load. Load Test shall generally conform to
provision made in IS 2911 (Part IV) which provides guidelines for determination of safe loads and
conducting of different types of tests.

20.5.2 Types of loadings/tests
(i) Vertical Load Test (Compression)
(ii) Cyclic Vertical Load Test
(iii) Lateral Load Test
20.5.3 Vertical Load Test

20.5.3.1 General: Compression load shall be applied to the pile top by means of a hydraulic jack
against suitable load frame which is capable of providing reaction and settlement is recorded by
suitable dial gauges. The contractor shall apprise of Engineer-in-Charge before test is conducted.
20.5.3.2 Preparation of Pile Head: Pile head shall be chipped off to horizontal plane, projecting
steel shall be cut or bent and top finished smooth and leveled with plaster of Paris or similar synthetic
material as specified to give a plane surface which is normal to the axis of the pile. A bearing plate
with a hole at the centers shall be placed on the head of pile for the jacks to rest.
20.5.3.3 Loading Platform: A proper loading platform is installed as specified. Contractor shall
ensure that when the hydraulic jack and load measuring devices are mounted on pile head the whole
system will be stable on the maximum specified load. For single pile two dial gauges shall be fixed to
the pile and bear on surfaces on reference frame. The dial gauges shall be placed in diametrically
opposite positions and be equidistant from the pile axis. Four dial gauges are used for groups,
having 0.01 mm sensitivity. The arrangement shall be approved by the Engineer-in-charge.
20.5.3.4 Application of Load: The test is carried out by applying a series of downward incremental
load (20 per cent of safe loads on pile). In this method application of increment of test load and
taking of measurement or displacement in each stage is maintained till the rate of displacement is
either 0.1 mm in first 30 minutes or 0.2 mm in first one hour or 2 hours, whichever occurs first. The
test load shall be maintained for 24 hours. This method is applicable for both initial and routine test.
For testing of raker piles the loading shall be along its axis. Safe load on single pile for initial test is
least of following:
(i) Two-thirds of the final load at which the total displacement attains a value of 12 mm unless
otherwise stated based on type of structure, in such case the safe load should be
corresponding to total displacement permissible.
(ii) 50 per cent of the final load at which the total displacement equal 10 per cent of pile
diameter and 7.5 per cent of bulb diameter in case of under-reamed piles.
Routine test shall be carried for a test load of one and half times the working load, maximum
settlement not to exceed 12 mm or as stated.
Safe load on group of piles for initial test shall be least of the two
(i) Final load at which total displacement is 25 mm or as stated based on type of structure.
(ii) Two-thirds of final load at which the total displacement is 40 mm.
Routine test shall be carried for a test load equal to not less than working load, the maximum
settlement not to exceed 25 mm.
20.5.3.5 Maintained Load Method: This is applicable for both initial and routine test. In this method
application of increment of test load and taking of measurement or displacement in each stage of
loading is maintained till rate of displacement of the pile top is either 0.1 mm in first 30 minutes or
0.2 mm in first one hour or till 2 hours, whichever occurs first. If the limit of permissible displacement
as given in 20.5.3.4 is not exceeded, testing of pile is not required to be continued further. The test
load shall be maintained for 24 hours.

Pile test data such as load, displacement and time shall be recorded in suitable prescribed tabular form.
Results can be presented by suitable curves.
Test shall be carried out in proper manner and to the entire satisfaction of the Engineer- in- charge. After
the test is completed the test cap shall be dismantled and pile surface shall be resorted to original shape.
20.5.3.6 Measurement: Each completed test shall be enumerated for initial test, routine test separately.
20.5.3.7 Rate: The rate includes the cost of labour, material and all the operations described above such as
preparatory work including installation of loading platform, applying load, preparing pile head for load test,
trimming of pile head etc. complete.
20.5.4 Cyclic Vertical Load Testing

20.5.4.1 General: This process shall be used in case of initial test to find out separately skin friction and point
bearing load on single piles of uniform diameter in conformity of provisions of IS Code 2911 (Part 4) for
conducting of the test.
20.5.4.2 Preparatory Pile Head: As per clause 20.5.3.2.
20.5.4.3 Loading Platform: As per clause 20.5.3.3
20.5.4.4 Application of Load: Relevant provision as per clause 20.5.3.4 shall be applicable. The test may be
continued up to 50 per cent over the safe load.
20.5.4.5 Test procedure given in Appendix E shall be followed.
Test shall be carried out in proper manner and to the entire satisfaction of the Engineer-in-charge.
After the test is completed, the test cap shall be dismantled and pile surface shall be restored to original
shape.
20.5.4.6 Measurement: Each completed test shall be enumerated for different load ranges.
20.5.4.7 Rate: The rate includes the cost of labour, materials and all the operations described above such as
preparatory work, trimming of pile head etc. complete.
20.5.5 Lateral Load Testing

20.5.5.1 Load Platform: A proper loading platform shall be installed as specified. Hydraulic jack is mounted
with gauge between two piles or pile groups under test. Dial gauge tips shall rest on central portion of glass
plate fixed on the side of pile.
20.5.5.2 Application of Load: Full load imposed by the jack shall be taken as lateral resistance on each pile
or group. Load should be applied in increments of about 20 per cent of the estimated safe load. The next
increment shall be applied after the rate of displacement is approximately equal to 0.1 mm per 30 minutes.
20.5.5.3 The safe lateral load on pile; is least of the following:

(i) Fifty per cent of the final load at which total displacement increases to 12 mm.
(ii) Final load when total displacement is 5 mm.
(iii) Load corresponding to any other specified displacement as per performance requirement.
Pile group shall be tested as per actual conditions as far as possible.

20.5.5.4 Displacements: Displacement is read by at least two dial gauges of 0.1 mm sensitivity
spaced at 30 cm and kept horizontally one above the other and displacement is interpolated at cut
off level. One dia gauge placed diametrically opposite to jack shall directly measure displacement.
Where, it is not possible to locate one of the dial gauges in the line of the jack axes, then two dial
gauge may be kept at a distance of 30 cm at a suitable height and the displacement interpolated at
load point from similar triangles.
Note: One of the methods of keeping dial gauge on pile surface is to chip off uneven concrete on the
side of the pile and to fix a piece of glass 20 to 30 mm square. The dial gauge tips shall rest on the
central portion of the glass plate.
Arrangement and test procedure shall be duly approved by the Engineer-in-Charge.
20.5.5.5 Measurement: Each completed test shall be enumerated for different load ranges.
20.5.5.6 Rate: The rate includes the costs of labour, materials and all the operations described
above.

APPENDIX A
BASIC PROPERTIES OF DRILLING MUD (BENTONITE)
[Clause 20.2.2.2 & 20.3.3 (iv)]
A- 1 Properties
A-1.1 The bentonite suspension used in bore holes is basically clay of montmorillonite group having
exchangeable sodium cat ions. Because of the presence of sodium cat-ions, bentonite on dispersion
will break down into small plate like particles having a negative charge on the surfaces and positive
charge on the edges. When the dispersion is left to stand undisturbed, the particles become oriented
building up a mechanical structure at its own. This mechanical structure held by electrical bond is
observable as a jelly like mass or jell material. When jelly is agitated, the weak electrical bonds are
broken and the dispersion becomes fluid.
A-2 Functions
A-2.2 In the case of granular soil, the bentonite suspension penetrates into the sides under positive
pressure and after a while forms a jelly. The bentonite suspension gets deposited on the sides of the
hole not penetrate into the soil, but deposits only a this film on the surface of the hole. Under such
condition, stability is derived from the hydrostatic head of the suspensions.
A-3 Specification
A-3.1 The bentonite suspension used for pilling work shall satisfy the following requirements:
The liquid limit of bentonite when tested in accordance with IS 2720 (Part V) 1985 shall be 400
percent or more.
(a)
(b) The sand content of the bentonite powder shall not be greater than 7 per cent.
Note: The purpose of limiting the sand content is mainly to control and reduce the wear
and tear of the pumping equipment.
(c) Bentonite solution should be made by mixing it with fresh water using pump for circulation.
The density of the bentonite solution should be between 1.03 to 1.10 gm/ml.
(d) The mash viscosity when tested by a Marsh cone should be between 30 and 60 stoke.
(e) The swelling index as measured by the swelled volume after 12 hours in abundant quantity
of water shall be at least 2 times its dry volume.
(f) The pH value of the bentonite suspension shall be between 9 and 11.5

APPENDIX B
EQUIPMENTS FOR UNDER-REAMED PILES (MANUAL CONSTRUCTION)
(Clause 20.3.3)
B-1 Equipment
B-1.1 Normally the following equipment will be required in manual operation:

(a) An auger;
(b) An under-reamer;
(c) A boring guide; and
(d) Accessories like spare extensions, cutting tool, concreting funnel etc.
B-1.1.1 For the piles of size larger than 30 cm and for larger depths additional equipment required
will be portable tripod hoist with a manually operated winch.
B-1.1.2 For piles in high ground water table and unstable soil conditions, boring and under-reaming
shall be carried out with bentonite slurry using suitable equipment. Tremie pipe shall be used for
concreting
(a) Drop weight for driving the core assembly, and
(b) Pipe or solid core.

APPENDIX C
PILE FRAME
Scope
Specification for pile frame shall be in conformity to the one laid in IS 6428. Contractor shall use
the proper height of pile frame and which is able to take the weight of hammer safety.
Standard size of pile frame will assist the user in determining the type and size of frame. Damages
pile frame which cannot be used for want of spares shall be replaced with sound one.
Size
The size of pile frame shall be designated by its height and the weight of the hammer and the pile
it can take.
The pile frame shall be as per the sizes given in table below:
S.No Size Height of Pile Frame Weight of hammer Weight of pile
(Any Type) max
1 I 7.5 1.5 3
2 II 10.5 3 6
3 III 15 5 10
4 IV 20 6 12
5 V 25 6 12
Extension Panels: All pile frames shall be capable of being fixed with extension panels of 1.5, 3
and 4.5 m height without reduction in weight capacity.
Performance: Pile frames with or without extension panels shall be capable of placing piles at
the maximum backward rake in 1 in 5 and the maximum forward rake 1 in 10.

APPENDIX D
PILE BORING EQUIPMENT- GENERAL REQUIREMENT

(Clause 20.2.2)
Scope
Specification for pile boring equipment shall be as per IS 14362. Constructions of bored piles
require careful selection of boring equipment. Choice of appropriate equipment will depend upon
subsoil conditions, diameter of pile, their depths and other specific requirements of any particular
work. Details of equipment and proposed methods of driving the pile shall be submitted by the
tenderer for scrutiny and approval by the competent authority
Equipment described herein refers to construction of bored piles on land and without the user of
bentonite. The standard nominal diameter of piles shall be 450 mm, 500 mm, 600 mm and the like.
Materials
All materials used in the construction of pile boring equipment shall conform to the requirement
of relevant Indian Standard IS 800 ‘Code of Practice’ for general construction in steel.
Pile Boring Equipment

General
The various items comprising pile boring equipment are:
(a) Winch
(b) Derrick
(c) Boring/chiseling tools
(d) Temporary casings
(e) Tremie arrangements, and
(f) Accessories
A typical piling winch consists of the following components as shown below in Fig. D1
(a) Winch drum,
(b) Prime mover,
(c) Transmission system,
(d) Clutch system,
(e) Brake system,
(f) Winch

Fig. D1
Winch Drum: This standard capacities (drum rope pull) of the winch drum shall be 5 t. And the drum
meter shall not be less than 20 times the diameter of the wire ropes used.
Prime Mover: The prime mover shall usually be a diesel engine of the air cooled type or an electric
motor. A suitable reduction gear shall also be provided.
Transmission: The transmission system shall be one of the following :

(a) Geared drive
(b) Chain drive, and
(c) Belt drive (flat belt or V-belt)
The transmission system shall be provided with suitable guard cover.
Clutch System: The clutch system shall consist of a clutch wheel and friction plate(s) or a Friction
cone operated by a lever.
Brake System: This shall consist of a brake band connected with the foot brake pedal or brake
handle for hand operation.
Winch Frame: A typical winch frame shall be made from structural steel section and shall be either
truck -mounted crawler-mounted or skid-mounted. A proper stabilizer shall be provided to transmit
the load to the ground smoothly.
Derrick
General: The standard derrick shall consist of the following components:
(a) Main shear leg,
(b) Side shear leg,

(c) Shear leg base,
(d) Pulley, and
(e) Safety link.
The hoisting capacity of the derrick shall be at least equal to the maximum drum rope pull land
preferably more by 25%.
Main Shear Leg: The main shear leg shall be a box section fabricated according to IS 800-1984 either from
two mild steel angle sections or two channel sections. The box section shall have minimum dimensions of
125 mm2 and the minimum length of the leg shall be 5.6 m.
Side Shear Legs: The two sides shear legs shall have a minimum box section of 100 mm2. One of the two
side legs shall be provided with suitable mild steel rings spaced 0.3 m apart up to the top. These legs shall be
placed part at as distance of minimum of 3 m.
Shear Leg Base: These shall consist of as steel plate welded to the base of the leg. Additional plates shall
be welded on all four sides of the leg for up to 15 mm above the bottom of the leg.
Pulley: The pulley shall be usually provided at the top of the main shear-leg and it shall have a diameter at
least 20 times the diameter of the wire-rope used. The pulley shall have a suitable guard and shall be properly
lubricated.
Safety Link: An interconnected steel -chain shall be provided near the top of the derrick so as to preclude any
accidental increase in the distances between the legs.
Boring/Chiseling Tools
The various tools shall be as follows:
(a) Sludge pump,
(b) Bailers,
(c) Chisels,
(d) Casings,
(e) Casing extractor plate,
(f) Casing extractor bar,
(g) Casing drive bar, and
(h) Tiller
Sludge Pump: Boring shall be usually advanced by using a sludge pump (also called shell) as shown in Fig.
D-2. Weight of the sludge ump shall vary with the diameter but normally minimum weight shall be 7.5 kN.
Sludge pump is a hollow cylindrical steel body with a cutting shoe at the bottom and a lifting hook at its top.
It has hinged trap door immediately above the bottom cutting edged and it has an opening (window) near the
top for muck removal. Above this window, lead or steel or concrete may be added to increase the weight of the
sludge pump for effective boring.
Bailer: The bailer (see Fig. D -3) is used for removal of water or slush from the bore hole. It is made up of a
hollow steel cylinder with a lifting hook at the top and a truncated base plate with perforation at the bottom.
There is a plunger passing through a central hole of the base plate which acts as a plug valve. This plunger is
about 20 cm long and has about 15 cm diameter steel plates welded at its top and bottom. This closes the
central hole in the base plate of the plunger and thus retains the slush material for removal.

Fig. D-2 : SLUDGE PUMP (SHELL) Fig. D-3 : BAILER
Chisels: Hard strata during boring shall be broken by chisels. The chisels shall be made of solid
round bar with hard faced edged at the bottom. The chisel shall weigh at least 7.5 KN for 450 mm
12.5 KN for 500 and 600 mm piles.
Casing: These shall be made from 16 mm thick plates and the standard length shall be 1.5 m. The
casings shall be threaded on both sides and suitable collar shall be used to protect the threads.
Casing Extractor Plate: A steel plate of suitable size shall be used for the extraction casing after the
boring operation is complete.
Casing Extractor Bar: his shall be a round of about 75 mm diameter. It shall be passed through the
holes only sides of the casing and through the extractor plate, to enable extractor of casing.
Casing Drive Bar: This shall have a cross-section of at least 75 mm2 and shall be used to drive the
casing.
Tiller: This gadget shall be used to rotate the casing manually, whenever necessary.
Temporary Casing
This shall consist of the following.
The casing collar shall be attached at the casing top to take the blows during casing driving.
The main casing shall be made from 16 mm thick steel and shall be threaded at one end.
The casing shall be provided with as cutting edge at the bottom to facilitate driving.

Tremie Arrangements
The tremie arrangements shall include the Following:
(a) Concrete hopper
(b) Hopper plug
(c) Tremie pipe
(d) Holding clamp and
(e) Hoisting plug.
Accessories
Accessories shall include the following:
(a) Concrete placer
(b) Wheel barrow
(c) Measuring chain
(d) Bailers
(e) Crowbars
(f) Dog-clamps with pins
(g) Steel measuring tape; and
(h) Mucking shovel.

APPENDIX E
CYCLIC LOAD TEST METHOD

(Clause 20.5.4.5)
E-1 Method
E-1.1 Alternate loading and unloading shall be carried out at each stage as in 20.5.3.5 and each
loading stage shall be maintained as in 20.5.5.2 and each unloading stage shall be maintained for at
least 15 minutes and the subsequent elastic rebound in the pile should be measured accurately by
dial gauges as in 20.5.5.5. The test may be continued up to 50 per cent over the sage load.
E-2 Analysis of Results for Frictional Resistance

E-2.1 Graphical Method
E-2.1.1 Assuming that there is no compression in the pile, plot a graph relating total elastic recovery
and load at the pile top.
E-2.1.3 Draw a straight line parallel to the straight portion of curve I to divide the load into two parts
and thereby obtained approximate values of point resistance and skin friction.
E-2.1.4 From the approximate value of skin friction, and knowing the loads of top of pile, compute the
elastic compression of the pile corresponding to these loads, by the following formula:
= (T-F/2)L
AE
Where
= Elastic compression of pile in cm, T = Load on pile top in kgf,
F = Frictional resistance in kgf, L = Length of the pile in cm,
A = Cross-sectional area of the pile in cm2, and
E = Modulus of elasticity of the pile material in kgf/cm3
(The value should normally be measured from an exposed portion of pile stem by means of
compress meter during the load test itself.)
E-2.1.5 Obtain values of the elastic compression of the sub grade by subtracting the elastic
compression of the pile from the total elastic recovery of pile, and plot the graph relating these new
values the negative value shall be ignored until the value is positive.
E-2.1.6 Repeat the procedures given in E-2.1.3 to obtain new values of skin friction.
E-2.1.7 The process of further approximations covered in E-2.1.6 may be repeated further to any
desired extent, but usually the third curve would give sufficiently accurate values for skin friction for
practical purposes.

E-2.2 Analytical Method Analysis of Cyclic Load Test Data for Separation of Skin
Frication and Point Resistance.
E-2.2.1 From straight line portion of curve calculate the value of constant from the equation.
m= s - ( T/AE)L
T
Where
m = A constant;
¨s = Change in total elastic settlement of pile
¨T = Change in applied load = (Tb– Ta) in kgf
L= length of pile in cm;
2
A= cross-sectional area of pile in cm
2
E= elastic modulus of the material of pile in kgf/cm
T= Load on pile top in kgf.
E-2.2.2 Calculate the corrected settlement for different load increment by equation (2)
S=mT
Where
S = Corrected settlement in cm, and
T= Total load on pile top in kgf.
E-2.2.3 Knowing value of m and S compute skin friction and point bearing by solving simultaneous
equation (3) and (4).
T =P+F
S = mP + (T-F/2)L
AE
Where
P= point bearing in kgf, and
F = skin friction in kgf.

APPENDIX F
PILE DRIVING HAMMER
(Clause 20.1.2)
Scope
Specifications for driving hammer shall be in conformity to the one laid in IS 6426. Driving hammer
of standard weight and strokes of different types be used.
The object should be to keep weights of hammers to a limited range and standardize weight
interval and stroke to facilitate their use with pilling rig & pilling attachments of different plants.
Piles may be driven with any type of hammer, provided they penetrate to the prescribed depth or
attain to ensure a final penetration of not more than 5 mm per blow.
Classification
It is preferable to employ the heaviest hammer practicable and to limit the stroke, so as not to
damage the pile. Pile hammers shall be classified as given in the Table below:
Table No. Classification of Pile Driving Hammers

S. No. Class Weight Kg
(1) (2) (3)
(i) Light Hammers Up to 500
(ii) Medium Hammers Over 500 and up to 2500
(iii) Heavy Hammers Over 2500
Sizes
The recommended sizes (weight of ram or striking part) and stroke of different types shall be as
given in Table below:
TABLE
Sizes (Weight of Ram or the Striking Part) and Stroke of Different Types of Hammers
S.No. Type of Light (upto 500 kg) Medium Heavy (Over

Hammers 9Over 500 up to 2500 kg) 2500 kg)
(1) (2) (3) (4) (5)
1 Drop Hammer 250 to 500 kg at multiples 750 to 2500 kg at 2750 to 4500 kg
of 125 multiples of 250 at multiples of
250
2 Single acting (a) 25 to 100 kg at 750 to 2500 kg at 3000 to 7500 kg
capable of multiples of 25 kg at multiples of 250, at at multiples of
working on maximum stroke of 20 maximum stroke of 90 500 kg at
steam or air at cm cm. maximum stroke
2
5.5 kg/cm at the (b) 100 to 500 kg at at 120 cm.
hammer multiples of 100 kg at
maximum stroke of 40
cm.
3 Double acting (a) 25 to 100 kg at 750 to 2500 kg at
capable of multiples of 25 kg at multiples of 500, at
working on maximum stroke of 20 maximum stroke of 45
steam or air at cm cm.
2
5.5 kg/cm at the (b) 100 to 500 kg at
hammer multiples of 100 kg at
cm.
4 Diesel Hammer 500 kg at maximum stroke Over 500 up to 2500 kg
of 250 cm at multiples of 500 kg at
cm.

SUB HEAD : 21.0
ALUMINIUM WORK
1119
CONTENTS
21.1 Aluminium 1127
21.2 Paneling Material 1128
21.3 EPDM Gaskets 1132
21.4 Sealant 1132
21.5 Reflective Glass 1133
21.6 Door, Window, Ventilator and Partition Frames 1134
21.7 Door, Windows and Ventilator Shutters 1135
21.8 Fittings 1153
21.9 Louvers 1153
21.10 Hermetically Sealed Unit 1153
21.11 Brass Lock 1154
21.12 Machine moulded Aluminium covering over 1154

expansion
21.13 Anodised Aluminium Grill 1155
21.14 12mm Thick Frameless Toughened Glass Door 1156

Shutter
21.15 Non Sag Elastomeric Polyurethane Sealant 1157
Fig. 21.1 Terminology for Aluminium Doors, Windows and 1135

Ventilators
Fig. 21.2 Types and Size of Aluminium Doors, Windows and 1136
Ventilators
Fig. 21.3 Extruded Aluminium Sections for Doors, Windows 1137

and Ventilators
1121 SUB HEAD 21.0 : ALUMINIUM WORK

Fig. 21.4 Location of Parts of Aluminium Doors, Windows and 1140
Ventilators for which Details are Shown
Fig 21.5 Mullion with Fixed Glass on one Side and Side 1141
Hung on Other Side
Fig 21.6 Mullion with Side Hung Shutter Both Sides 1141
Fig 21.7 Coupling Section Extruded for Coupling Windows 1141

Side by Side
Fig 21.8 Detail Through Bottom of Top-Hung Ventilator 1141
Fig 21.9 Coupling Section Extruded having Weather Bar 1141

Fitted with Ventilators on top of Windows
Fig 21.10 Weather Bar over Extruded Opening Shutter with 1142
Fixed Light Above
Fig 21.11 Detail of Aluminium Double Shutter Door 1142
Fig. 21.12 Typical Projecting Type Hinge for Side-Hung Shutters 1143
Fig. 21.13 Typical Non-Projecting Type Hinge for Side-Hung 1144

Shutters
Fig. 21.14 Illustration Showing Working Principle of Friction Stay 1144
Fig. 21.15 A Typical Handle for Side-Hung Shutter 1145
Fig. 21.16 Position of Handle Plates in Relation to Heights of 1145

'HS' Type Windows
Fig. 21.17 A Typical Peg-Stay for Side-Hung Shutters and 1145

Top-Hung Ventilators
Fig. 21.18 Detail Through Jamb Showing Turnbuckle 1146
Fig. 21.19 Typical Rotor Operator for Side-Hung Shutters 1146

Fitted with Fly Screens
Fig. 21.20 Detail of Horizontal Centre-Hung Ventilator 1147
Fig. 21.21 Spring Catch for Centre-Hung Ventilator 1147
Fig. 21.22 Cord Eye and Pulley Arrangement for Centre-Hung 1147
Ventilator

Fig. 21.23 Typical Projecting Type Hinge for Door 1148
Fig. 21.24 Typical Non-Projecting Type Hinge for Door 1148
Fig. 21.25 Typical Door Handle 1149
Fig. 21.26 Typical Vertical Bolt for Double Shutter Door 1149
Fig. 21.27 Typical Three-Way Bolting Device for Doors 1150
Fig. 21.28 Coupling Section Extruded for Coupling Door to 1150

Window or Side Light
Fig. 21.29 Chart Showing Approximate Position of Fixing Holes 1151

and Number of Fixing Lugs

LIST OF BUREAU OF INDIAN STANDARD (BIS) CODES

1. IS 733 Wrought Aluminium and Aluminium Alloys, Bars, Rods and
Sections (For General Engineering Purposes) -Specification
2. IS 737 Wrought Aluminium and Aluminium alloy sheet and strip for
general engineering purposes -Specification
3. IS 1285 Wrought Aluminium and Aluminium Alloy, Extruded Round
Tube and Hollow sections (For General Engineering
Purposes) - Specification
4. IS 1868 Anodic coating on Aluminium and its Alloys-Specification
5. IS 1948 Specification for Aluminium Doors, Windows and Ventilators
6. IS 3908 Specification for Aluminium equal leg angles
7. IS 3909 Specification for Aluminium unequal leg angles
8. IS 3965 Dimensions for wrought Aluminium and Aluminium Alloys bars,
rods and sections.
9. IS 5523 Method of testing anodic coating on aluminium and its alloys.
10. IS 6012 Measurement of coating thickness by Eddy Current Method
11. IS 6315 Floor springs (Hydraulically regulated) for heavy doors-
Specifications
12. IS 6477 Dimensions of extruded hollow section and tolerances
13. IS 12823 Wood products- Pre-laminated particle board -Specifications.
14. IS 14900 Transparent Float glass- Specifications.

21.0 ALUMINIUM WORK
21.0 TERMINOLOGY
Bar
Any solid section, other than round, with at least one dimension of 10 mm or more.
Rod
Any round solid section with a diameter of 10 mm or greater.
Extruded Round Tube

A circular hollow extrusion of uniform wall thickness not subjected to cold drawing.
Hollow Section
An extruded shape other than round tube, the cross section of which completely encloses a void
or voids and which is not subject to cold drawing.
Anodized Aluminium
Aluminium with an anodic coating, produced by an electrolytic oxidation process, in which the
surface of the aluminium is covered with a coating, generally an oxide, to give protective and decorative
properties.
Pre-laminated Particle Board

A particle board laminated on both surface by synthetic impregnated base papers under the
influence of heat and pressure with finished foil under the pressure or pressure and heat depending
on type of binder used.
Floor Spring (Hydraulically Regulated)

A device used to close the door so as to slow down its speed before it reaches its closed position.
Single Action Floor Spring (Hydraulically Regulated)

A device used to close the door in one direction only so as to slow down its speed before it
reaches to its closed position.
Double Action Floor Spring (Hydraulically Regulated)

A device used to close the door in both directions so as to slow down its speed before it reaches
its closed position.
Shoe
The device fixed to the bottom of the door leaf in order to hoist it to the floor spring.
Top Centre Pivot

The device to secure the upper portion of the door leaf and the door frame above.
Right Hand Floor Spring

A floor spring suitable for use on an anticlockwise door; an anticlockwise door is one which when
viewed from above, rotates in anticlockwise direction about its hinge while opening.
Left Hand Floor Spring

The floor spring suitable for use on clockwise door a clockwise door is one which, when viewed
from above, rotates in clockwise direction about its hinge while opening.
Sash
It is a complete window unit whether fixed or open type.

Composite Window
Window unit having two or more sashes joined together with one or more coupling members.
Centre – Hung Ventilator

A ventilator horizontally pivoted at the centre on both sides. Top half opens inwards and bottom
half opens outwards.
21.1 ALUMINIUM
21.1.1 Aluminium Sections
Aluminium sections used for fixed/openable windows, ventilators, partitions, frame work & doors
etc. shall be suitable for use to meet architectural designs to relevant works and shall be subject to
approval of the Engineer-in- Charge for technical, structural, functional and visual considerations.
The aluminium extruded sections shall conform to IS 733 and IS 1285 for chemical composition and
mechanical properties. The stainless steel screws shall be of grade AISI 304.
The permissible dimensional tolerances of the extruded sections shall be as per IS 6477 and
shall be such as not to impair the proper and smooth functioning/operation and appearance of door
and windows.
Aluminium glazed doors, windows etc. shall be of sizes, sections and details as shown in the
drawings. The details shown in the drawings may be varied slightly to suit the standards adopted by
the manufacturers of the aluminium work, with the approval of Engineer-in-Charge. Before proceeding
with any fabrication work, the contractor shall prepare and submit, complete fabrication and installation
drawings for each type of glazing doors, windows, ventilators and partition etc. for the approval of
the Engineer-in- Charge. If the sections are varied, the contractor shall obtain prior approval of
Engineer-in-Charge and nothing extra shall be paid on this account.
21.1.2 Anodising
Standard aluminium extrusion sections are manufactured in various sizes and shapes in wide
range of solid and hollow profiles with different functional shapes for architectural, structural glazing,
curtain walls, doors, window & ventilators and various other purposes. The anodizing of these products
is required to be done before the fabrication work by anodizing/electro coating plants which ensures
uniform coating in uniform colour and shades. The extrusions are anodized up to 30 micron in different
colours. The anodized extrusions are tested regularly under strict quality control adhering to Indian
Standard.
21.1.3 Powder Coating

21.1.3.1 Material: The powder used for powder coating shall be Epoxy/polyester powder of make
approved by the Engineer- in-Charge. The contractor shall give detailed programme for powder
coating in advance, to facilitate the inspection by Engineer-in-Charge or his authorized representative.
21.1.3.2 Pre-treatment: Each aluminium alloy extrusion or performed section shall be thoroughly
cleaned by alkaline or acidic solutions under the conditions specified by chemical conversion coating
supplier and then rinsed. A chemical conversion coating shall be applied by treatment with a solution
containing essentially chromate ions or chromate and phosphate ions as the active components as
applicable. The amount of the conversion coating deposited depends on the type used by the
conversion coating chemical supplier. The conversion coating shall be thoroughly rinsed either with
the solution specified by the conversion coating chemical supplier or with de-mineralized water and
then dried at the temperature for the time specified by the conversion coating chemical supplier. The
contractor shall submit the detail specifications and application procedure for application of conversion
coating for approval of Engineer- in-Charge. The metal surface after the conversion coating
pretreatment and prior to the application of the coating shall be free from dust or powdery deposits.

21.1.3.3 Process: The polyester powder shall be applied by electrostatic powder spray method.
Before start of powder coating the contractor shall submit detail specification for application of polyester
powder from manufacturer of the polyester powder for approval of Engineer-in-Charge. The powder
coating shall be applied as per the specification approved by Engineer-in-Charge.
21.1.3.4 Thickness: The thickness of the finished polyester powder coating measured by micron
meter shall not be less than 50 micron nor more than 120 micron at any point.
21.1.3.5 Performance Requirements for the Finish

(i) Surface appearance: The finish on significant surfaces shall show no scratches when
illuminated and is examined at an oblique angle, no blisters, craters; pinholes or scratches
shall be visible from a distance of about 1 m. There shall not be any visible variation in the
colour of finished surfaces of different sections and between the colours of different surfaces
of same section.
(ii) Adhesion: When a coated test piece is tested using a spacing of 2 mm between each of the
six parallel cuts (the cut is made through the full depth of powder coating so that metal
surface is visible) and a piece of adhesive tape, approximately 25 mm x 150 mm approved
by the Engineer-in-Charge is applied firmly to the cut area and then removed rapidly by
pulling at right angles to the test area, no pieces of the finish other than debris from the
cutting operation shall be removed from the surface of the finish.
21.1.3.6 Protection of Powder Coated / Anodizing Finish : It is mandatory that all aluminium members
shall be wrapped with self adhesive non-staining PVC tape, approved by Engineer-in-Charge.
21.1.3.7 Measurement: All the aluminium sections including snap beading fixed in place shall be
measured in running meter along the outer periphery of composite section correct to a millimeter.
The weight calculated on the basis of actual average (average of five samples) weight of composite
section in kilogram correct to the second place of decimal shall be taken for payment. (Weight shall
be taken after anodizing). The weight of cleat shall be added for payment. Neither any deduction nor
anything extra shall be paid for skew cuts.
21.1.3.8 Rate: The rate shall include the cost of all the materials, labours involved in all the operations
as described in nomenclature of item and particular specification.
21.2 PANELING MATERIAL

21.2.1 Pre-laminated Particle Board
A particles board laminated on both surfaces by synthetic resin impregnated base papers under
heat and pressure. Pre -laminated particle boards shall be of two grades, namely, Grade I and II
corresponding to IS 3087 & 12823. Each of the grades specified shall be of four types, namely,
Types-I, II, III, and IV classified by the surface abrasion characteristics specified in Table 21.1. The
grade and types of pre-laminated particle board shall be represented by symbols as follows:
Grade Type Designation
Grade 1 Type I PLB-11
Type II PLB-12
Type III PLB-13
Type IV PLB-14
Grade 1 Type I PLB-21
Type II PLB-22
Type III PLB-23
Type IV PLB-24

TABLE 21.1
Physical and Mechanical Properties
(Para 21.2.1)
Sl. No. Properties Flat Pressed Three Layer, Multilayer
and Graded
Grade-I Grade-II
(i) Density variation (Max.) Percent ± 10 ± 10
(ii) Water absorption (Max )
(a) 2 hours 7.0 15.0
(b) 24 hours 15.0 30.0
(iii) Thickness swelling (Max.), percent, 2 hours 5.0 8.0
(iv) Modulus of rupture (Min) N/mm2
(a) Up to 20 mm thickness 15.0 11.0
(b) Above 20 mm thickness 12.5 11.0
(v) Tensile strength perpendicular to surface
(Min.) N/m2
(a) Up to 20 mm thickness 0.45 0.3
(b) Above 20 mm thickness 0.4 0.3
(vi) Tensile strength perpendicular to surface
(Min.) N/mm2
(a) After cyclic test* 0.2 -
(b) After accelerated water resistance test** 0.15 -
(vii) Screw withdrawal strength (Min.), N:
(a) Face 1250 1250
(b) Edge 850 750
(viii) Abrasion resistance (Min.) in number of
revolutions
(a) Type I 450 450
(b) Type II 250 250
(c) Type III 80 80
* Cyclic Test : Specimen are immersed in water at 27±2o C for a period of 72 hours, followed by drying
in air at 27 ± 2o C for 24 hours and then heating in dry air at 70o C for 72 hours. Three such cycles are
to be followed and then specimens are tested for tensile strength perpendicular to the surface.
** Accelerated Water Resistance Test: Specimens are immersed in water at 27±2o C and water is
brought to boiling and kept at boiling temperature for two hours. Specimens are then cooled in water
to 27±2o C and tested for tensile strength perpendicular to the surface.
21.2.1.1 Particle Board: Synthetic resin bonded flat pressed three layers, multilayer and graded particle
board defined in IS 3087 having superfine surface shall be used for production of prelaminated particle board.
For ECO Marks the particle board shall also conform to the requirements of ECO Mark specified in IS 3087.
21.2.1.2 Impregnated Base Paper: Printed or plain coloured absorbent base paper having a weight of 60 -140
g/m2 impregnated in a suitable synthetic resin and dried to a volatile content of 4-8 per cent shall be used for
pre-lamination on both surfaces of particle board.
21.2.1.3 Impregnated Overlay: An absorbent tissue, paper having a weight of 18-40 g/m2 impregnated in a
suitable synthetic resin and dried to a volatile content of 4-8 per cent shall be used for the manufacture of pre-
laminated particle board.
21.2.1.4 Manufacture: Particle boards having superfine and closed surface with high face strength and steep
density gradient across the thickness is used for making prelaminated particle boards. Impregnated base
papers rich in a synthetic resin are placed on either side of the particle board and the assembly is taken
inside a short cycle single opening lamination press or a multi day light press. Under heat and pressure the
resin flows and forms a permanent bond with particle board.

The top surface of impregnated paper comes in contact with special surface chromium plates or steel
caul plates and takes the impression of surface finish of these cauls. Hot boards are extracted out of the short
cycle press and cooled in air, whereas cooling of boards is done inside the dress in multiday light type. Care
should be taken to keep cycle times low in the press to avoid heat penetration to the centre of the boar edge.
The impregnated overlay paper may be used by placing it over the impregnated base paper (IBP) on one
surface while using a normal IBP on the other surface and pressure. The impregnated overlay becomes
transparent after pressing. Such boards are used for high surface abrasion application.
In case of finished foil particle boards, the finished foil is pasted on both surfaces of particle board after
spreading suitable synthetic glue on board’s surface and passing the assembly in a roller press or a flat press
under the influence of pressure and/or heat depending on the type of binder used.
21.2.1.5 Finish: The finish of the paper overlaid board depends on the surface of caul plates used.
Common surface finishes in use are glossy, matt textured (soft, Swede, wood pore and leather), etc.
The surface finish of the foil finished boards depends on the original finish of the foil used.
21.2.1.6 Dimensions and Tolerances: Dimensions and tolerances shall conform to IS 12049.
21.2.1.7 Testing: One sample for every 100 sqm. or part thereof shall be taken and testing done as per
IS 12823. For quantity less than 100 sqm, the test certificate from manufacturer shall be relied upon. The
Engineer-in-charge may ask for testing even if the quantity is less than 100 sqm.
21.2.2 Aluminium Sheet
21.2.2.1 Aluminium Sheets for use as panels shall be 1.25 mm thick aluminium alloy sheet conforming to IS
737. Aluminium alloy sheet for use in general paneling work shall be of types and thickness as specified and
conforming to the requirement of IS 737. Aluminium sheets shall be of approved make and manufacturer.
Aluminium panel may be prefabricated units manufactured on modular or non-modular dimension.
21.2.2.2 Fixing: The required size of panel, keeping sufficient margin to be inserted inside the section, shall
be cut to correct size and fixed firmly in the frame with CP brass or aluminium or stainless steel screws of
star headed, counter sunk and matching size groove. Joints sealed with epoxy resin or silicon sealant to
make the unit water proof.
21.2.3 Float Glass
21.2.3.1 The glass shall be clear float glass and should be approved by the Engineer in Charge. It shall be
clear, float transparent and free from cracks subject to allowable defects. The float glass shall conform to the
IS 14900.
21.2.3.2 Thickness : The thickness of float glass shall depend on the size of panel. The tolerance in thickness
shall be as under:
TABLE 21.2
Nominal Thickness (in mm ) Tolerance (in mm )
4.0 ± 0.3
5.0 ± 0.3
6.0 ± 0.3
8.0 ± 0.6

21.2.3.3 Allowable Defects: The allowable defects shall be as per Table 21.3 below:
TABLE 21.3
Sl. No. Defects Central Outer Remarks
1. Gaseous inclusion. Max size, 3.0 6.0 Separated by at least 30.0 cm
mm
2. Opaque gaseous inclusion. 3.0 6.0 Separated by at least 60.0 cm
Max size. mm
3. Knots, dirt and stones, Max 1.0 1.0 Separated by at least 30.0 cm
size. mm
4. Scratches, Rubs and Crush Faint Light Separated by at least 30.0 cm
5. Bow, percent. Max 0.5 0.5 See 21.2.4.3
6. Reams, Strings and lines Light Light See 21.2.4.4
7. Waviness Nil Nil See 21.2.4.5
8. Sulphur stains Nil Nil
9. Corner breakage and chip Not more than nominal
thickness of float glass
21.2.3.4 Allowable Cluster of Defects: The allowable cluster of defects mentioned under Sl. No. 1,
2 & 3 of Table 21.3 shall be as per IS 14900.
21.2.4 Tests
21.2.4.1 Thickness: The thickness of float glass shall be measured with micrometers or a caliper
which is graduated to 0.01 mm or with a measuring instrument having an equivalent capacity.
21.2.4.2 Scratches, Rubs and Crush : Place the sample of float glass in a vertical position
approximately 50 cm from the viewer’s position and look through it using either day light without
direct sunlight or a background light suitable for observing each type of defect.
Intensity of Scratches, Rubs, Crush Intensity Distance Limit
Faint Shall not be detectable beyond 50 cm
Light Detectable between 50-100 cm and not beyond 100 cm.
21.2.4.3 Bow : Depending on the side on which bow is present, stand the sample vertically on a
wooden plank. Stretch a thread edge to edge. Measure the longest perpendicular. Distance from the
thread to the surface of float glass facing the thread and express it as percentage of the length of
float glass from edge along the thread.
21.2.4.4 Reams, Strings and Lines : Focus a light projector with a 500 W lamp and an objective lens
with an approximate 5 cm aperture and about 30 cm focal length on a flat white projection screen
placed about 760 cm from the light source in a dark room. Place the float glass in a vertical position
parallel to the screen between the light and the screen. Move the glass slowly towards the screen
with a vertical oscillating motion. The shadowgraph read out is the distance at which the distortion
just blends with the general shadow of the glass on the screen.
TABLE 21.4
Intensity of Reams, Strings and Lines Intensity Distance Limit
Light 7.5 cm
Medium 5.0 cm
Heavy 2.5 cm
21.2.4.5 Perspective Distortion: When tested as per test procedure described below it shall not
give distorted vision of straight stripe pattern.

Test Procedure for Perspective Distortion
Perspective distortion shall be examined by looking through the specimen glass which may be
placed at about 4.5 m distance in such a direction that the incident angle to it is 50 degree (4 mm or
above) and by observing a screen set up perpendicularly to the line of vision about 4.5 m further
ahead of the specimen over the total width of about middle part of the specimen from the horizontal
direction. The specimen glass shall be kept with the drawn direction at manufacture vertical and, on
the surface of the screen, the strip pattern of white and black parallel straight lines of 25 mm width
and inclined 45 degrees from the vertical shall be provided and its surface shall be luster less.
21.3 EPDM- GASKETS

The EPDM Gaskets shall be of size and profile as shown in drawings and as called for, to render
the glazing, doors, windows, ventilators etc. air and water tight. Samples of gaskets shall be submitted
for approval and the EPDM gasket approved by Engineer- in- Charge shall only be used. The
contractor shall submit documentary proof of using the above material in the work to the entire
satisfaction of Engineer-in-Charge.
The EPDM gasket shall meet the requirements as given in Table 21.5 below:
TABLE 21.5
Sl. No. Description Standard Follow Specification
1 Tensile strength Kg.f/cm2 ASTM-D 412 70 Min.
2 Elongation at break % ASTM-D 412 250 Min.
3 Modulus 100% Kgf/cm2 ASTM-D 412 22 Min.
4 Compression set % at 0o CC 22 Hrs. ASTM-D 395 50 Max.
5 Ozone resistance ASTM-D 1149 No visible cracks
21.4 SEALANT
21.4.1 The sealants of approved grade and colour shall only be used. The silicone for perimeter
joints (between Aluminium section and RCC/Stone masonry) shall be of make approved by the Engineer
in Charge.
21.4.2 Method of Application

Surface Preparation : Clean all joints and glazing pockets by removing all foreign matter and
contaminants such as grease, oil, dust, water, frost, surface dirt, old sealants or glazing compounds
and protective coatings.
21.4.3 Masking
Areas adjacent to joints shall be masked to ensure neat sealant lines. Masking tape shall not be
allowed to touch clean surfaces to which the silicone sealant is to adhere. Tooling shall be completed
in one continuous stroke immediately after sealant application and before a skin forms and masking
shall be removed immediately after tooling.
21.4.4 Application
Install backer rod of appropriate size and apply silicone sealant in a continuous operation using
a positive pressure adequate to properly fill and seal the joint. The silicone sealant shall be tooled
with light pressure to spread the sealant against backing material and the joint surfaces before a
skin forms. A tool with convex profile shall be used to keep the sealant within the joint. Soap or water
shall not be used as a tooling aid. Remove masking tape as soon as silicone joint is tooled.
Tolerance: A tolerance of + 3 mm shall be allowed in the width of silicone joints. The depth of the
joints at throat shall not be less than 6 mm.

21.5 REFLECTIVE GLASS
21.5.1 Definitions
(i) Shading Coefficient: The shading coefficient is the ratio of total solar transmittance to the
transmittance through 3.2 mm (1/8") clear glass. Windows with low shading coefficient values
improve comfort for building, lower the total cooling load of the building and help smooth out of the
difference in cooling loads between perimeter & core zones.
(ii) Luminous Efficacy Constant (Ke) indicates a windows relative performance in rejecting solar
heat-while transmitting day light. It is the ratio of the visible transmittance to the shading coefficient;
clear glass which lets in roughly equal amounts of visible light and solar near-infrared energy has a
Ke close to 1.0. The solar radiation contains about 50% invisible near-infrared & ultra violet light.
Therefore, a perfectly selective glazing, which would all allow visible light pass through while blocking
all of the invisible near-infrared & ultraviolet light, would have Ke of about 2.0.
(iii) Resistance to Heat Conduction (R-valve): It is a measure of resistance to heat flow that occurs
because of temperature difference between the two sides of the windows. The inverse of R-value is
termed as U-value.
21.5.2 Reflective Glass

This is an ordinary float glass with a metallic coat to reduce solar heat. Clear glass transmits most of the
sunlight that shines upon it, and most of the solar heat as well; the metallic coated glass i.e. reflective glass
has better shading coefficients because they reflect rather than absorb infrared energy. However, most of
reflective glazing blocks day light more than solar heat.
21.5.2.1 Types of Coatings: There are two types of reflective glass, Pyroltic (Hard) coated and vacuum (soft) coated.
(i) Pyroltic : It is a coating applied during glass manufacture. The coating is fused into the glass at 1200°C.
(ii) Vacuum Coated Glass: It involves the deposition of metal particles on the glass surface by a chain
reaction in a vacuum vessel. It is often called a soft coat; because the coating is more susceptible
to damage than hard coat glass. Where toughening of product is required, the product must be
toughened first & then vacuum coated. Vacuum coated products have better shading coefficient
values than pyroltic products.
21.5.2.2 Performance of Reflective Glass: The performance of reflective glass 6 mm of nominal thickness is
given below:
Sl. No. Parameter Threshold Ratio In %age
1 Visible Light
- Transmittance (%) 15-46
- Reflectance (%) 12-24
2 Total Solar Energy:
- Reflectance (%) 8-12
3 Ultra Violet Rays:
4 U-Value
- Summer 0.58
- Winter 0.45
5 Shading Coefficient 0.25-0.35
21.5.2.3 Testing: The reflective glass shall be tested for the followings:
(i) Physical/Field Test: In a true reflective glass, when a pointed pencil is placed, then tip of
pencil (physical) & image should coincide.
(ii) Lab. Test: In the lab, the reflective glass shall be tested for the parameter specified in
21.5.2.2 above.
21.5.2.4 Fixing of glass shall be done as specified.

21.6 DOOR, WINDOW, VENTILATOR AND PARTITION FRAMES
21.6.1 Frame Work
First of all the shop drawings for each type of doors/windows/ventilators etc. shall be prepared by
using suitable sections based on architectural drawings, adequate to meet the requirement/
specifications and by taking into consideration varying profiles of aluminium sections being extruded
by approved manufacturers. The shop drawings shall show full size sections of glazed doors, windows,
ventilators etc. The shop drawings shall also show the details of fittings and joints. Before start of the
work, all the shop drawings shall be got approved from the Engineer-in-Charge.
Actual measurement of openings left at site for different type of door/window etc. shall be taken.
The fabrication of the individual door/windows/ventilators etc. shall be done as per the actual sizes of
the opening left at site. The frames shall be truly rectangular and flat with regular shape corners
fabricated to true right angles. The frames shall be fabricated out of section which have been cut to
length, mitered and jointed mechanically using appropriate machines. Mitered joints shall be corner
crimped or fixed with self tapping stainless steel screws using extruded aluminium cleats of required
length and profile. All aluminium work shall provide for replacing damaged/broken glass panes without
having to remove or damage any member of exterior finishing material.
21.6.2 Fixing of Frames

The holes in concrete/masonry/wood/any other members for fixing anchor bolts/fasteners/screws
shall be drilled with an appropriate electric drill. Windows/doors/ventilators etc. shall be placed in
correct final position in the opening and fixed to Sal wood backing using stainless steel screws of star
headed, counter sunk and matching size groove. of required size at spacing not more than 250 mm
c/c or dash fastener. All joints shall be sealed with approved silicone sealants.
In the case of composite windows and doors, the different units are to be assembled first. The
assembled composite units shall be checked for line, level and plumb before final fixing is done.
Engineer -in-Charge in his sole discretion may allow the units to be assembled in their final location
if the situation so warrants. Snap beadings and EPDM gasket shall be fixed as per the detail shown
in the shop drawings.
Where aluminium comes into contact with stone masonry, brick work, concrete, plaster or dissimilar
metal, it shall be coated with an approved insulation lacquer, paint or plastic tape to ensure that
electrochemical corrosion is avoided. Insulation material shall be trimmed off to a clean flush line on
completion.
The contractor shall be responsible for the doors, windows etc. being set straight, plumb, level
and for their satisfactory operation after fixing is complete.
21.6.3 Measurements
All the aluminium sections including snap beadings fixed in place shall be measured in running
meter along the outer periphery of composite section correct to a millimeter. The weight calculated
on the basis of actual average (average of five samples) weight of composite section in kilogram
correct to the second place of decimal shall be taken for payment (weight shall be taken after
anodizing). The weight of cleat shall be added for payment. Neither any deduction nor anything extra
shall be paid for skew cuts.
21.6.4 Rate
The rate shall include the cost of all the materials, labour involved in all the operations as described
in nomenclature of item and particular specification.

21.7 DOOR, WINDOWS AND VENTILATOR SHUTTERS
Material, fabrication and dimensions of aluminium doors, windows and ventilators manufactured
from extruded aluminium alloy sections of standard sizes and designs complete with fittings, ready
for being fixed into the building shall be as per IS 1948.
21.7.1 Terminology
The components of doors, windows and ventilators shall be defined as in Figure 21.1 below.
Fig. 21.1 : Terminology for Aluminium Doors, Windows and Ventilators
21.7.2 Standard Sizes, Tolerances and Designations

The types and the overall sizes of aluminium doors, windows and ventilators shall be as given in
Figure 21.2. Their sizes are derived after allowing 1.25 mm clearances on all the four sides for the
purpose of fitting the doors, windows and ventilators into modular openings.

Note : 1. Windows without horizontal glazing bars shall be designated by ‘N’ in place of ‘H’ in the
range shown.
Note : 2. Doors and side lights shall only be coupled with 12 module (117.5 cm) high windows.
All dimensions in centimetres
Fig. 21.2 : Types and Size of Aluminium Doors, Windows and Ventilators

21.7.3 Tolerances
The sizes for doors, windows and ventilators frames shall not vary by more than ±1.5 mm.
21.7.4 Material
Aluminium alloy extruded sections used in the manufacture of extruded window sections shall
conform to IS 733. Hollow aluminium alloy sections used shall conform to IS 1285. Dimension and
weight per metre run of the extruded sections shall be as given in Figure 21.3.
Note 1 : All radii R = 1.6 mm

Note 2 : The weights of sections per metre length as indicated are nominal.
Fig. 21.3 : Extruded Aluminium Sections for Doors, Windows and Ventilators
21.7.5 Glass Panes

Glass panes shall weigh at least 7.5 kg/m2 and shall be free from flaws, specks or bubbles. All
panes shall have properly squared corners and straight edges. The sizes of glass panes for use in
doors, windows and ventilators shall be as given in Table 21.6.
21.7.6 Screws
Screws threads of machine screws used in the fabrication of aluminium doors, windows and
ventilators shall conform to IS 1362.

TABLE 21.6
Glass Sizes (Clearance Allowed)
(Clause 21.7.5)
Designation Quantity Glass size Width X Designation Quantity Glass size Width X
Height cm Height cm
No Glazing Bar Fixed Type No Glazing Bar Centre-Hung Type
6NF6 1 53.0 x 53.0 6NC6 1 46.0 x 46.0
10NF6 2 45.0 x 53.0 10NC6 2 42.5 x 46.0
12NF6 2 55.0 x 53.0
12NC6 2 52.5 x 46.0
15NF6 {2 45.0 x 53.0 15NC6 {2 45.0 x 53.0
{1 47.5 x 53.0 {1 43.5 x 46.0
18NF6 {2 55.0 x 53.0 18NC6 {2 55.0 x 53.0
{1 57.5 x 53.0 {1 53.5 x 46.0
6NF9 1 53.0 x 83.0 8NC6 1 66.0 x 46.0
10NF9 2 45.0 x 83.0 No Glazing Bar Side-Hung Type
12NF9 2 55.0 x 83.0
15NF9 {2 45.0 x 83.0 6NS9 1 50.0 x 80.0
{1 47.5 x 83.0 10NS9 2 43.5 x 80.0
18NF9 {2 55.0 x 83.0 12NS9 2 52.5 x 80.0
{1 57.5 x 83.0 15NS9 {2 43.5 x 80.0
6NF12 1 53.0 x113.0 {1 47.5 x 83.0
10NF12 2 45.0 x 113.0 18NS9 {2 52.5 x 80.0
12NF12 2 55.0 x 113.0 {1 57.5 x 83.0
15NF12 {2 45.0 x 113.0 6NS12 1 50.0 x 110.0
{1 47.5 x 113.0 10NS12 2 43.5 x 110.0
18NF12 {2 55.0 x 113.0
{1 57.5 x 113.0 12NS12 2 52.5 x 110.0
6NF15 {1 53.0 x 27.0 15NS12 {2 43.5 x 110.0
{1 53.0 x 113.0 {1 47.5 x 113.0
10NF15 {2 {45.0 x 27.0 18NS12 {2 53.0 x 27.0
{2 {45.0 x 113.0 {1 50.0 x 110.0
12NF15 {2 55.0 x 27.0 6NS15 {1 53.0 x 27.0
{2 55.0 x 113.0 {1 50.0 x 110.0
15NF15 {2 45.0 x 27.0 10NS15 {2 45.0 x 27.0
{1 47.5 x 27.0
{2 45.0 x 113.0 {2 43.5 x 110.0
{1 47.5 x 113.0 12NS15 {2 55.0 x 27.0
18NF15 {2 55.0 x 27.0 {2 52.5 x 110.0
{1 57.5 x 27.0 15NS15 {2 45.0 x 27.0
{2 55.0 x 113.0 {1 47.5 x 27.0
{1 57.5 x 113.0 {2 43.5 x 110.0
8NF6 1 73.0 x 53.0 {1 47.5 x 113.0
6NF21 {1 53.0 x 84.5 18NS15 {2 55.0 x 27.0
{1 53.0 x 27.5 {1 57.5 x 27.0
{1 53.0 x 56.0 {2 52.5 x 110.0
No Glazing Bar Top-Hung Type {1 57.5 x 113.0
6NT6 1 50.0 x 50.0
8NS21 {1 66.0 x 81.0
10NT6 2 44.5 x 50.0
12NT6 2 54.5 x 50.0 {1 56.0 x 27.5
15NT6 {2 45.0 x 53.0 {1 66.0 x 56.0
{1 45.5 x 50.0 12NS21 {2 50.5 x 81.0
18NT6 {2 55.0 x 53.0 {2 50.5 x 56.0
{1 54.5 x 50.0 {1 50.5 x 27.5
8NT6 1 70.0 x 50.0 {1 40.5 x 27.5
6NT9 {1 50.0 x 51.5
{1 53.0 x 27.5

Designation Quantity Glass size Width X Designation Quantity Glass size Width X
Height cm Height cm
Horizontal Glazing Bar Fixed Type Horizontal Glazing Bar Centre-Hung Type
6HF6 2 53.0 x 26.0 6HC6 2 46.0 x 22.5
10HF6 4 45.0 x 26.0 10HC6 4 42.5 x 22.5
12HF6 4 55.0 x 26.0 12HC6 4 52.5 x 22.5
15HF6 {4 45.0 x 26.0 15HC6 {4 45.0 x 26.0
{2 47.5 x 26.0 {2 43.5 x 22.5
18HF6 {4 55.0 x 26.0 18HC6 {4 55.0 x 26.0
{2 57.5 x 26.0 {2 53.5 x 22.5
6HF9 {2 53.0 x 27.5 8HC6 2 66.0 x 22.5
{1 53.0 x 26.0 Horizontal Glazing Bar Side-Hung Type
10HF9 {4 45.0 x 27.5 6HS9 3 50.0 x 26.0
{2 45.0 x 26.0 10HS9 6 43.5 x 26.0
12HF9 {4 55.0 x 27.5
12HS9 6 52.5 x 26.0
{2 55.0 x 26.0 15HS9 {6 43.5 x 26.0
15HF9 {4 45.0 x 27.5 {2 47.5 x 27.5
{2 45.0 x 26.0
{2 47.5 x 27.5 {1 47.5 x 26.0
18HS9 {6 52.5 x 26.0
{1 47.5 x 26.0 {2 57.5 x 27.5
18HF9 {4 55.0 x 27.5
{2 55.0 x 26.0 {1 57.5 x 26.0
{2 57.5 x 27.5 6HS12 {2 50.0 x 26.0
{1 57.5 x 26.0 {2 50.0 x 27.5
10HS12 {4 43.5 x 26.0
6HF12 4 53.0 x 27.5
10HF12 8 45.0 x 27.5 {4 43.5 x 27.5
12HS12 {4 52.5 x 26.0
12HF12 8 55.0 x 27.5
15HF12 {8 45.0 x 27.5 {4 52.5 x 27.5
{4 47.5 x 27.5 15HS12 {4 43.5 x 26.0
18HF12 {8 55.0 x 27.5 {4 43.5 x 27.5
{4 57.5 x 27.5 {4 47.5 x 27.5
6HF15 {1 53.0 x 27.0 18HS12 {4 52.5 x 26.0
{4 53.0 x 27.5 {4 52.5 x 27.5
10HF15 {2 45.0 x 27.0 {4 57.5 x 27.5
{8 45.0 x 27.5 6HS15 {1 53.0 x 27.0
12HF15 {2 55.0 x 27.0 {2 50.0 x 26.0
{8 55.0 x 27.5 {2 50.0 x 27.5
15HF15 {2 45.0 x 27.0 10HS15 {2 45.0 x 27.0
{1 47.5 x 27.0 {4 43.5 x 26.0
{8 45.0 x 27.5 {4 43.5 x 27.5
{4 47.5 x 27.5 12HS15 {2 55.0 x 27.0
18HF15 {2 55.0 x 27.0 {4 52.5 x 26.0
{1 57.5 x 27.0 {4 52.5 x 27.5
{8 55.0 x 27.5 15HS15 {2 45.0 x 27.0
{4 57.5 x 27.5 {1 47.5 x 27.0
8HF6 2 73.0 x 26.0 {4 43.5 x 26.0
6HF21 6 53.0 x 27.5 {4 43.5 x 27.5
Horizontal Glazing Bar Top-Hung Type {4 47.5 x 27.5
6HT6 2 50.0 x 24.5 18HS15 {2 55.0 x 27.0
10HT6 4 44.5 x 24.5 {1 57.5 x 27.0
12HT6 4 54.5 x 24.5 {4 52.5 x 26.0
15HT6 {4 45.0 x 26.0 {4 52.5 x 27.5
{2 44.5 x 24.5 {4 57.5 x 27.5
18HT6 {4 55.0 x 26.0 8HS21 {1 66.0 x 24.0
{2 54.5 x 24.5 {4 66.0 x 27.5
6HT9 {1 50.0 x 26.0 {1 56.0 x 27.5
{1 50.0 x 24.5 12HS21 {2 50.5 x 24.0
{1 53.0 x 27.5 {9 50.5 x 27.5
8HT6 2 70.0 x 24.5 {1 40.5 x 27.5

21.7.7 Fabrication
Frames: Frames shall be square and flat, the corners of the frame being fabricated to a true right
angle. Both the fixed and opening frames shall be constructed of sections which have been cut to
length, mitered and welded at the corners. Where hollow sections are used with welded joints, argon-
arc welding or flash butt welding shall be employed (gas welding or brazing not to be done).
Subdividing bars of units shall be tenoned and riveted into the frame.
The location of the parts and details of construction of the doors, windows and ventilators are
indicated in Fig. 21.4 to 21.11.
Fig. 21.4 : Location of Parts of Aluminium Doors, Windows and Ventilators for
which Details are Shown

Fig 21.5 : Mullion with F
Fixed Glass on one Side and Side Hung on Oth
ther Side
Fig 21.6 : Mu
ullion with Side Hung Shutter Both Sides
Fig 21.7 : Coupling Se

ection Extruded for Coupling Windows Side by
y Side
Fig 21.8 : Detail Through Botto

tom of Fig 21.9 : Coupling Section Extruded d having Weather
Top-Hung Ventilator Bar Fitted with Ventilators on top
p of Windows

Fig 21.10 : Weather Bar over Extruded Opening Shutter with Fixed Light Above
Fig 21.11 : Detail of Aluminium Double Shutter Door

21.7.8 Side-hung Shutters
For fixing aluminium alloy hinges, slots shall be cut in the fixed frame and the hinges inserted
inside and may be riveted to the frame. The hinges shall normally be of the projecting type 67 mm
wide (Fig. 21.12). The aluminium alloy for cast hinges shall conform to IS Designation A-5-M of IS
617. Specification for Aluminium and Aluminium Alloy Ingots and Castings for General Engineering
Purpose and for extruded section of hinges to IS Designation HE10-WP or HE30-WP of IS 733. The
pins for hinges shall be of stainless steel of non-magnetic type or aluminium alloy HR30. Irrespective
of hinges being anodized or not, the aluminium alloy pins shall be anodized to a minimum film thickness
of 0.025 mm shall be sealed with oil, wax or lanolin. Non- projecting types of hinges may also be used
where ever required. (Fig. 21.13).
Frictions hinges may be provided for side-hung shutter windows, in which case peg stay may not
be required. The working principle of the friction hinges is illustrated in Fig. 21.14.
The handle for side- hung shutters shall be of cast aluminium conforming to IS Designation A-5-
M of IS 617 and mounted on a handle plate welded or riveted to the opening frame in such a way that
it could be fixed before the shutter is glazed. The handle should have anodized finish with minimum
anodic film thickness of 0.015 mm. The handle shall have a two points nose which shall engage with
an aluminium striking plate on the fixed frame in a slightly open position as well as in a fast position
(Fig. 21.15). The height of the handles in each type of side-hung shutters shall be fixed in approximate
position as indicated in Fig. 21.16.
Fig. 21.12 : Typical Projecting Type

Hinge for Side-Hung Shutters

Fig. 21.13 : Typical Non-Projecting Type Hinge
for Side-Hung Shutters
Fig. 21.14 : Illustration Showing Working Principle of Friction Stay

Fixing Screw
33 mm
Shake Proof
Washer
3m
mm
Wed
edge Shape
Strik
triking Plate
11 mm Round
or Square Hole
4 mm
10.3 mm
Fig. 21.15 : A Typical Handle for Side-Hung Shutter
Fig. 21.16: Position of Hand

ndle Plates in Relation to Heights of ‘HS’ Type Win
indows
Stay for Side-Hung Shutters and Top-Hung Venti

Fig. 21.17 : A Typical Peg-S tilators

The peg stay shall be either of cast aluminium conforming to IS 617 or folded from IS Designation
NS4 aluminium alloy sheet conforming to IS:737 specification for wrought aluminium and aluminium
alloys, Sheet and strip. It shall be 300 mm long, complete with peg and locking brackets (Fig. 21.17).
The stay shall have holes for keeping the shutter open in three different positions. The peg and locking
bracket shall be riveted or welded to the fixed frame.
Alternatively, and if specifically required by the purchaser, side- hung shutters may be fitted with an
internal removable fly screen of 0.375 mm wire and equivalent to IS Sieve 100 in a 0.900 mm
aluminium alloy sheet conforming to IS Designation NS3-1/2H of IS 737 applied to the outer frame of
the shutter by case or extruded aluminium alloy turn-buckle at the jambs (Fig. 21.18) and by aluminium
or plated bronze shoes at the sill to allow of the screen being readily removed, and with a rotor
operator at the sill to permit the operation of the shutter through an angle of 90º (Fig. 21.19). On fly-
screened shutters the peg stay is omitted and the normal handle shall be replaced by a locking handle
to hold the shutter in the fast position.
Fig. 21.18 : Detail Through Jamb Fig. 21.19 : Typical Rotor Operator for Side-Hung
Showing Turnbuckle Shutters Fitted with Fly Screens
21.7.9 Top-Hung Ventilators
The aluminium hinges for top- hung ventilators shall be either cast or fabricated out of extruded
sections and shall be riveted to the fixed rail after cutting a slot in it. The aluminium alloy for cast
hinges shall conform to IS Designation A-5-M of IS 617 and the extruded section of hinge to IS
Designation HE10-WP or HE30_WP of IS 733
The pegs stay shall be 300 mm long as in side-hung shutter (Fig. 21.17). The locking bracket shall
be fixed to the fixed frame.
21.7.10 Centre-Hung Ventilators (Fig.21.20)

Centre hung ventilators shall be hung on two pairs of cup pivots of aluminium alloy to IS
Designation NS-4 of IS 737 and IS Designation A-5- M of IS 617 or on brass or bronze cup pivots
which should be either chromium or cadmium plated and riveted to the inner and outer frames of the
ventilators to permit the ventilator to swing through an angle of approximately 85º. The opening portion
of the ventilator shall be so balanced that it remains open at any desired angle under normal weather
condition.
Cast aluminium conforming to IS Designation A-5-M of IS 617 or bronze which shall be either
chromium-plated or cadmium-plated spring catch shall be fitted in the centre of the top bar of the
ventilators for the operation of the ventilator. This spring catch shall be secured to the frame and shall
close into aluminium catch plate riveted or welded to the outside of the outer ventilator frame bar (Fig.
21.21).

Fig. 21.20 : Detail of Horizontal Centre-Hung Ventilator
Fig. 21.21: Spring Catch for Centre-Hung Ventilator
Aluminium or cadmium plated brass cord pulley -wheel in an aluminium bracket shall be fitted at
the sill of the ventilator with aluminium or galvanized or cadmium plated steel screw or, alternatively,
welded together with an aluminium cord eye riveted or welded to the bottom inner frame bar of the
ventilator in a position corresponding to that of pulley (Fig. 21.22).
21.7.11 Doors
The outer fixed frame shall be of section A1-FX8. The shutter frame shall be of either hollow
sections A1-HFX5 and A1-HFX6 (Fig. 21.3 and Fig. 21.11).

The kick panels shall be of 1.25 mm aluminium alloy sheet conforming to IS Designation NS3-1/2H
of IS 737 specification for Wrought Aluminium and Aluminium Alloys, Sheet and strip and shall be
screwed to the frame and the glazing bar.
Hinges –Cast of extruded aluminium alloy hinges for doors shall be of the same type as in the
windows but of larger size. The hinges shall normally be of the 50 mm projecting type (Fig. 21.23).
Non-projecting type of hinges may also be used (Fig. 21.24).
The handle for doors may be of the design indicated in Fig. 21.25.
A suitable lock for the door operable either from inside or outside shall be provided.
Note: From the point of view of security, the lock which is operable from only one side is better and in
the case of such locks, a bolt shall be provided to make them inoperable from the other side.

Fig. 21.25 Typical Door Handle
In double shutter doors the first closing shutter shall have a concealed aluminium alloy bolt at top
and bottom (Fig. 21.26). It shall be so constructed as not to work loose or drop by its own weight.
Single and double shutter doors may be provided with a three-way bolting device (Fig. 21.27).
Where this is provided in the case of double shutter door, concealed aluminium bolts may not be
provided.
Fig. 21.26 : Typical Vertical Bolt for Double Shutter Door

Fig. 21.27 : Typical Three-Way Bolting Device for
Doors 21.7.12 Composite Units
The doors shall be coupled to windows or side-lights by extruded aluminium sections made from
aluminium alloy conforming to IS Designation HE9-WP of IS 733. The coupling member should
conform to the dimensions indicated in Fig. 21.28.
Fig. 21.28 : Coupling Section Extruded for Coupling Door to Window or Side Light

21.7.13 Weather Bar
Where a coupling member is fitted over an external opening shutter, the coupling member should
incorporate an integrally extruded weather bar (Fig. 21.9).
21.7.14 Position of Bolts, Fixing Screws and Lugs

Outer frames shall be provided with fixing holes centrally in the web of the sections in the position
(Fig. 21.29). Moreover, any steel lugs coming in contact with aluminium should be either galvanized or
given one coat of bituminous paint.
Fig. 21.29 : Chart Showing Approximate Position of Fixing Holes and Number of Fixing Lugs

The fixing screws and lugs shall be as given in Table 21.7
TABLE 21.7
Sl. No Place of Fixing Size of Screw or Lug
(i) To wooden frames rebated on the outside 30 mm x No. 10 galvanized woodscrews.
(ii) To plugs in concrete, stone or brick work -Do-
rebated on the outside
(iii) To plugs in concrete, stone or brick work 45 mm X No. galvanized wood-screws
not rebated on the outside (that is plain or
square jambs)
(iv) Direct to brick work or masonry (that is Slotted steel adjustable lugs (natural finish)
plain or square jambs) not less than 100 x 16 x 3 mm countersunk
galvanized machine screws and nuts 19.0 X
6.3 mm
(v) To steel work Standard clips and 8 mm galvanized bolts
with hexagonal nuts.
21.7.15 Finish
Alumiumum doors, windows and ventilators may be supplied in either matt, scratch-brush or
polished finish. They may, additionally, also be anodized, if so required by the Engineer-in-charge. If
colour anodizing is to be done then only approved light-fast shades should be used.
A thick layer of clear transparent lacquer based on methacrylates or cellulose butyrate, shall be
applied on aluminium doors, windows and ventilators by the supplier to protect the surface from wet
cement during installation. This lacquer coating shall be removed after installation is completed.
21.7.16 Glazing
Glazing shall be provided on the outside of the frames
If required, glazing clips may be provided as extra fittings. Four glazing clips may be provided per
glass pane, except for door type 8HS21 where the glazing clips shall be six per glass pane. In case of
doors, windows and ventilators without horizontal glazing bars the glazing clips shall be spaced
according to the slots in the vertical members, otherwise the spacing shall be 30 cm.
Note: Glazing clips are not usually provided for normal size glass panes. Where large size glass
panes are required to be used or where the door or the window is located in heavily exposed
situation, holes for glazing clips have to be drilled prior to fabrication and cannot be done at any
later stage. Use of glazing clips, where necessary, shall be specified while placing the order.
21.7.17 Packing
All doors, windows and ventilators shall be dispatched with the opening parts suitably secured to
preserve alignment when fixing and glazing.
Fixing lugs, coupling fittings and all hardware shall be dispatched separately.
Composite windows shall be dispatched uncoupled.
21.7.18 Marking
All doors, windows and ventilators shall be suitably marked on the frames with a mark identifying
the manufacturer and the type.
The units may also be marked with the BIS Certification Mark.

21.8 FITTINGS
21.8.1 Stainless Steel Friction Stay
The stainless steel friction stays of make approved by the Engineer-in-Charge shall be used.
The SS friction stays shall be of grade AISI-304 and of sizes specified in nomenclature of item.
21.8.2 Lockable Handles

The lockable handle shall be of make approved by the Engineer-in-Charge and of required
colour to match the colour of powder coated /anodized aluminium window sections.
21.8.3 Hydraulic Floor Spring

The hydraulic floor spring shall be heavy duty double action floor spring of make approved by the
Engineer -in-Charge suitable for door leaf of weight minimum 100 kg. The top cover plate shall be of
stainless steel, flushing with floor finish level. The contractor shall cut the floor properly with stone
cutting machine to exact size & shape. The spindle of suitable length to accommodate the floor finish
shall be used. The contractor shall give the guarantee duly supported by the company for proper
functioning of floor spring at least for 10 years.
21.8.4 Tubular Handle

The tubular handle bar shall be aluminium polyester powder coated minimum 50 micron to required
colour/anodized AC 15. Outer dia of tube shall be 32 mm, tube thickness 3.0 mm and centre to centre
length 2115 mm + 5 mm.
21.8.5 Measurement
Refer Para 21.6.3.
21.8.6 Rate
Refer Para 21.6.4.
21.9 LOUVERS
Aluminium extruded sections (anodized or power coated) are used for providing Louvers in
aluminium door, window & partition for ventilation.
21.9.1 Fabrication
Refer Para 21.6.1.
21.9.2 Measurements
Refer Para 21.6.3.
21.9.3 Rate
Refer Para 21.6.4.
21.10 HERMETICALLY SEALED UNIT

Insulating glass shall be a double glazed unit comprising two sheets of float glass panes separated
by a spacer, hermetically sealed using primary and secondary sealants. The design of insulating
glass system shall consist of:
(a) Hollow Spacer Bar
The hollow aluminium spacer bar shall be of required size and shape and shall be colour
anodized. The spacer bar shall have two lines of perforations in the inner surface.
(b) Desiccant
The desiccant shall be Neftomol 3 A Chemetall or equivalent.

The desiccant filled in the aluminium spacer bar shall be synthesized crystalline compounds
of Aluminium Hydroxide, Caustic Soda and Sodium Silicate which absorbs water molecules.
The desiccant shall be of 3 A size (A means Angstrom). The quantity of desiccant used
shall not be less than 35 gm/m length of spacer bar. Filled spacer bar frame shall not be
stored for more than 6 hours before assembly and sealing of the unit to ensure proper
functioning of the desiccant. The contractor shall submit documentary proof of using the
above material in the work.
(c) Primary Sealant
The primary sealant shall be single component approved by the Engineer in Charge, thermo
plastic solvent free sealing compound based on polysosutylene. The sealant surface shall
be free from cavities, depression and other defects. The contractor shall submit
documentary proof of using the above material in this work.
(d) Secondary Sealant
The secondary sealant in double glazed unit shall be silicone sealant approved by the
Engineer in Charge. The contractor shall submit documentary proof of using the above
material in this work to the entire satisfaction of Engineer-in-Charge. Before application of
silicone/ polysulphide, the surface must be cleaned and free from oil, grease, dust and
other loose matter. The surfaces shall be cleaned with alcohol or other suitable solvents.
Detergent or soap shall not be used to clean the surfaces. The polysulphide shall be mixed
and applied mechanically using automatic mixing machine in the manner approved by
Engineer-in-Charge.
Measurement
The height and width of double glazed/single glazed unit (the area of glass unit outside the snap
beading shall only be measured) as fixed in place shall be measured correct to one centimeter and
area calculated in sqm. correct to second place of decimal shall be taken for payment.
Rate
The rate shall include the cost of all the materials, labours involved in all the operations as
described in nomenclature of item and particular specification.
21.11 BRASS LOCK

This should generally conform to IS-2209. The size of the lock shall be denoted by the length of
the body towards the face and it shall be 100 mm. the measured length shall not vary more than 3
mm from the specified length. Ordinary lever mechanism with not less than 2 levers shall be provided.
False lever shall not be used. Lever shall be fitted with one spring of phosphor- bronze or steel wire
and shall withstand the test as provided in IS-2209. Locking-bolt spring and strike plate shall conform
to IS 2209. Two keys shall be provided with each lock.
21.12 MACHINE MOULDED ALUMINIUM COVERING OVER EXPANSION

21.12.1 Material
The material to be used shall be wrought aluminium and aluminium alloy sheet confirming to IS
737 having anodic coating of AC-15 as per IS 1868 and epoxy/ polyester powder coating of minimum
50 microns and not more than 120 microns at any point. The anodic coating and epoxy/ polyester
powder coating shall be of approved colour and shade as directed by the Engineer-in-charge.
The cover plate should be made of wrought aluminium and aluminium alloy sheet of thickness
not less than 2.5mm. The covering sheet should be moulded aluminium, machine cut and machine
holed for receiving dash fasteners with single or double anti slip serrations ready to accommodate
horizontal thermal movement of approved size, shape, pattern and design fixed over expansion
joints on vertical surfaces/ ceilings/ floors.
Standard protective coating should be placed on aluminium surfaces which are coming in contact
with cementitious material as per manufacturers specification.

21.12.2 Installations
The substrates should be prepared as per drawing, instructions of the manufacturer and should account
for anchors, fasteners and other accessories to cover the expansion joint. The sheet to be fixed to cover the
expansion joint should be brought at site in required shade, size, shape, mould, design and pattern properly
cut, milled and drilled holes in one row on one side to accommodate designated stainless steel dash
fasteners of 8mm dia and 75mm long bolt including aluminium washers 2mm thick and 15mm dia at a
staggered pitch of 200mm centre to centre in the receiving surface and providing expandable plastic sleeves
in holes etc. complete as per direction of the Engineer-in-charge.
1. Necessary repairs with shrinkage resistant grout as required shall be used for preparing the surfaces
on which the expansion joint covering is to be installed/ fixed.
2. True alignment and proper relationship to joints and adjoining finished surfaces measured from
established lines and levels.
3. Adjustments should be made for differences between actual structural gap and nominal design gap
due to ambient temperature at time of installation.
4. Fix ends to accommodate thermal expansion and contraction without buckling.
5. Fix stainless steel dash fasteners of 8mm dia and 75mm long with aluminium washers 2mm thick
and 15mm dia at a staggered pitch of 200mm centre to centre.
6. Provide in continuous lengths for straight sections.
7. Install with hairline mitered corners where expansion joint cover assemblies change direction of
abut other materials.
8. Terminate exposed ends of expansion joint cover as per direction of Engineer-in-charge.
21.12.3 Measurement
The finished length and breadth of the aluminium sheet shall be measured correct to milimetres and area
calculated in Sqm correct to second place of decimal. The weight calculated on the basis of actual average
(average of five samples) weight of composite section in kilogram correct to the second place of decimal shall
be taken for payment (weight shall be taken after anodizing).
21.12.4 Rate
The rate shall include the cost of all the materials, labours involved in all the operations above and as
described in the nomenclature of item and particular specification.
21.13 ANODISED ALUMINIUM GRILL

21.13.1 Material
The aluminium grill should be of approved designed and pattern as directed by the Engineer-in-charge.
Standard aluminium section confirming to IS 733 and IS1285 for chemical composition and mechanical properties
shall be used to meet the architectural requirements and designed to relevant works and shall be subject to
approval of the Engineer-in-charge for technical, structural, functional and visual considerations. The stainless
steel screws to be used shall be of grade AISI 304. The anodic coating shall be of grade AC15 and shall
confirm to IS 6012. The permissible dimensional tolerances of aluminium sections shall be as per IS 6477 and
shall be such that in no case it impairs the proper and smooth functioning/ operation and appearance of the
door and window.
21.13.2 Fixing of Aluminium Grill

The shop drawings for each type of openings shall be prepared by using suitable approved sections based
on architectural drawings, adequate to meet the requirement/ specifications and by taking into consideration
varying profiles of aluminium sections being extruded by approved manufacturers. The shop drawings shall
show full size sections of doors, windows, ventilators and other openings etc. The shop drawings shall also
show the details of fitting and the openings to be made for the smooth operations of that fittings. Before start
of the work, all the shop drawings shall be got approved from the Engineer-in-charge.

Actual measurement of openings left at site for different type of door/window etc. shall be taken. The
fabrication of the individual doors/windows/ventilators etc. shall be done as per the actual sizes of the opening
left at site.
The anodised aluminium grill shall be of approved design and pattern with standard section from the
approved manufacturer. The grill of required size keeping sufficient margin to be inserted inside the section
shall be cut to correct size and fixed firmly in the frame with approved CP brass, aluminium or stainless steel
screws of star head, counter sunk and matching size. Screws threads used in the fabrication shall confirm to
IS1362. Proper opening of the size appropriate for fixing and operation of handles and other fittings shall be
made by cutting the grill to the size as per direction of the Engineer-in-charge.
21.13.3 Measurement
The length and breadth of the grill shall be measured correct to milimetres and area calculated in Sqm
correct to second place of decimal. The weight calculated on the basis of actual average (average of five
samples) weight of composite section in kilogram correct to the second place of decimal shall be taken for
payment (weight shall be taken after anodizing).
21.13.4 Rate
The rate shall include the cost of all the materials, labours involved in all the operations above and as
described in the nomenclature of item and particular specification.
21.14 12MM THICK FRAMELESS TOUGHENED GLASS DOOR SHUTTER

21.14.1 Material
This is a clear 12mm toughened safety glass frameless shutter having a consulate top and bottom self
closer mechanism with a pivot connecting to a discrete metal patch fitting at the top and bottom corners to the
door.
21.14.2 Application
The 12mm thick clear toughened safety glass frameless shutter is fixed with the help of corner patch
fittings. The corner patch fittings are simply a bolt through glass metal fitting requiring a corner cut out and
hole in the glass. These discrete corner patch fittings provide a sleek and clean frameless look. The lock body
patch fitting can also be installed where there is a necessity to provide locking arrangements for frameless
shutter. The maximum size of frameless doors shutters using corner patch fittings should not exceed from
1000mm X 2400mm. Bigger size doors should not be fixed with these fittings. The figure 21.18.1 shows the
fixing of frameless door shutters with top and bottom corner patch fittings.
Fig. 21.30

The frameless toughened glass door shutters of required thickness as specified in the item
should be installed with the help of 304 grade stainless steel patch fittings of approved brand and
manufacturer. These fittings should be complete in all respect with top and bottom pivots and double
action hydraulic floor spring types fixing arrangement. These fittings should be based on a modular
system, consisting of a base unit, functional inserts, and clip-on covers in a wide range of finishes.
The fittings should be suitable to support the weight of the complete glass door in such a way that the
movement of the door is smooth and free. The fittings should be got approved from the engineer-in-
charge and all the fixings etc. shall be done as per manufacturer specification and corresponding
codes described in the description of the fitting.
21.14.4 Measurement
The finished final length/ height and width of the glass door should be measured correct to two
places of decimal and overall area in sqm correct to two places of decimal should be calculated for
payment.
21.14.5 Rate
The rate shall include the cost of all the materials, labours involved in all the operations above
and as described in the nomenclature of item and particular specification.
21.15 NON SAG ELASTOMERIC POLYURETHANE SEALANT

21.15.1 Material
A weather protective non sag elastomeric construction sealant should be one component all
purpose, moisture cured, polyurethane premium grade sealant confirming to ASTM C 920 type S,
grade NS, class 35. This is to, be used as specified in the nomenclature of the item in accordance
with the product manufacturers specifications and as directed by the Engineer-in-charge.

All surfaces, joints, walls must be sound, clean, dry, frost-free, and free of oil, grease and any
other contaminants.
No priming is required or necessary usually. Priming is only required on the substrates which
indicates the need of priming under testing conditions. In the situation where priming seems to be
necessary after conducting the tests the manufacturer’s technical representative should be consulted.
2.15.3 Masking
Area adjacent to joints shall be masked to ensure neat sealant lines. Masking tape shall be
allowed to touch clean surfaces to which the sealant is to adhere. Tooling shall be completed in one
continuous stroke immediately after sealant application and before a skin forms and masking shall
be removed immediately after tooling.
21.15.4 Application
The closed cell backer rod of appropriate size shall be installed and the sealant should be
applied in continuous operation with positive pressure adequate to fill and seal the joint. Polyurethane
sealant should be gunned into joint when joint slot is at mid-point of its designed expansion and
contraction. Place nozzle of gun into bottom of the joint and fill entire joint. Keep the nozzle in the
joint, continue on with a steady flow of sealant preceding the nozzle to avoid air entrapment. The
cartridge once opened should be used and consumed the very same day. Avoid overlapping of
sealant to eliminate entrapment of air. Tool with convex profile as required and closed cell backer rod
of approved quality and size is recommended to ensure full contact with joints, walls and to remove
air entrapment. Remove masking tape as soon as sealant is tooled.

The closed cell backer rod is primarily a foam material with a surface skin. Make sure that backer
rod is 25% larger than joint width (under compression) to offer good tooling base. The sealant
should be applied by the caulking gun by putting the cartridge into the gun and putting the nozzle to
the base of the joint.
Tolerance: A tolerance of + 3mm shall be allowed in sealant for joint filling.
21.15.5 Curing
Allow one week to cure the polyurethane construction sealant under standard condition. The
contact with alcohol other solvent cleaners during cure should be avoided.
21.15.6 Measurement
The length should be measured in metres correct two places of decimal.
21.15.7 Rate
The rate shall include the cost of all the materials, labours involved in all the operations above
and as described in the nomenclature of item and particular specification.

SUB HEAD : 22.0
WATER PROOFING TREATMENT
1159
CONTENTS
22.1 Integral Cement based Treatment for Water 1166

Proofing on Horizontal Surface of Under-Ground
Structure at all depths
22.2 Integral Cement based Water Proofing Treatment 1168

on the Vertical Surface of Under-Ground Structures
22.3 Water Proofing Treatment to Vertical and Horizontal 1169

Surfaces of Depressed Portion of WC, Kitchen and
the like
22.4 Providing Water Stops 1170
22.5 Water Proofing Treatment in Sunken Portion of 1172

WCs, Bathrooms etc.
22.6 Water Proofing Treatment on Roof Slabs 1173
22.7 Integral Cement based Water Proofing Treatment 1174

with Brick Bat Coba
22.8 Water Proofing Treatment with Bitumen Felt 1176
22.9 Grading Roof with Cement Concrete 1:2:4 1181
22.10 Grading Roof with Cement Mortar 1182
22.11 Water Proofing Treatment with APP (Atactic 1183

Polypropylene Polymeric) Membrane (Shifted to
SH:14 as 14.49)
22.12 Five Layered Water Proofing treatment with Atactic 1183

Polypropylene Polymer Modified Prefabricated
Membrane (Shifted to SH:14 as 14.50)
22.13 Extra for Covering of Atactic Polypropylene Modified 1183

Prefabricated Membrane with Geotextile (Shifted to
SH:14 as 14.51)
1161 SUB HEAD 22.0 : WATER PROOFING TREATMENT

22.14 Water proofing treatment with integral crystalline 1183
admixture
22.15 Fibre reinforced elastomeric liquid water proofing 1186

membrane with resilient acrylic polymers

water proofing coating / slurry
22.17 Polymer modified flexible cementitious negative side 1190

waterproofing coating with elastic waterproofing
polymers

water proofing dry-shake
22.19 Crystalline water proofing mortar 1194
22.20 Swellable type water stop tape 1196
Appendix A Bitumen Felts (Fibre Hessian Base) 1199
Appendix B Glass Fibre Base Bitumen Felt 1201
Fig. 22.1 Waterproofing of Horizontal Surface of a U.G. 1202

Structure
Fig. 22.2 Water Proofing Horizontal Surfaces from Inside of 1202

a U.G. structure
Fig. 22.3 Waterproofing on Vertical Surfaces of Under 1203

Ground structures
Fig. 22.4 Position of Horizontal and Vertical Waterproofing 1203

Treatment in Sunken Portion of W.C./Kitchen and
the like
Fig. 22.5 Typical Cross-Section of PVC Water-Stop 1204
Fig. 22.6 Integral Cement based Waterproofing Treatment 1204

with Brick-bat Coba Over a RCC Slab
Fig. 22.7 Water Proofing 1205
Fig. 22.8 Grading Roof Slab with Cement Concrete 1205

Fig. 22.9 Grading Roof with Cement Mortar 1:3/1:4 1206
Fig. 22.10 Grading Chhajja with Cement Mortar 1:3/1:4 1206
Fig. 22.11 Five Course Water Proofing Treatment with APP

Modified Polymeric Membrane (Shifted to SH:14 as
Fig No.14.7)
Fig. 22.12 Five Layer Water-Proofing Treatment with APP

Modified Prefabricated Membrane (Shifted to
SH:14 as Fig No.14.11)


1. IS 73 Paving Bitumen Specifications
2. IS 702 Specifications for Industrial Bitumen
3. IS 1322 Specifications for Bitumen felts for Water Proofing and Damp
Proofing.
4. IS 2645 Specifications for Integral Cement Water Proofing Compounds
5. IS 3370 (Part -1) Code of Practice for Concrete Structures for the Storage of
Liquid: Part -1 General Requirements.
6. IS 3384 Specifications for Bitumen Primer for Water Proofing and
Damp Proofing
7. IS 7193 Specification for Glass Fibre Bitumen Felts
8. IS 12200 Provision of Water Stops at Transfers Construction Joints in
Masonry and Concrete Dams - Code of Practice.
9. IS 12432 (Part-3) Application for Spray Applied Insulation - Code of Practice
Part-3 Polyurethane/ Polyisocyarurate

22.0 WATER PROOFING TREATMENT
22.0 TERMINOLOGY
Water Bars
Water bars are preformed strips of impermeable materials which are embedded in the concrete
during construction.
Low Partition Walls

Parapet walls of height less than 45 cm.
Expansion Joints
Joints provided in the structure to allow for thermal expansion/construction.
Blended Cement
Cement mixed with water proofing compound in liquid or powder form.
22.1 INTEGRAL CEMENT BASED TREATMENT FOR WATER PROOFING ON HORIZONTAL

SURFACE OF UNDER-GROUND STRUCTURE AT ALL DEPTH
22.1.1 Water Proofing of Horizontal Internal Surfaces of Under-ground Structure (Fig. 22.1)
(i) Preparation of Surface
The Water Proofing Treatment over the lean concrete/levelling course surface should adhere
to the surface firmly, the surface of levelling course should be roughened properly when
the concrete is still green. In case the surface is not made rough before the concrete is set,
the work of water proofing should not be executed till proper key is provided for the base
layer of Cement Mortar 1:3.
(ii) Blending Cement/Water with Water Proofing Compound
The required quantity of cement bags to be used for a particular portion of work should be
emptied on a dry platform. Water proofing compound bearing ISI mark and conforming to IS
2645 should then be mixed properly with the cement. The quantity of water proofing
compound to be mixed should be as prescribed by the manufacturer but not exceeding 3%
by weight of cement. The quantity of cement and water proofing compound thus mixed
should be thoroughly blended and the blended cement should again be packed in bags.
For the water proofing compound in liquid form, the blending is to be done with water. This
can be done by taking the just required quantity of water to be mixed in the particular batch
of dry cement mortar.
The required quantity of water thus collected per batch of dry cement mortar to be prepared
should be mixed with liquid water proofing compound from sealed tins with ISI mark. The
water thus mixed with water proofing compound shall be thoroughly stirred so that the
water is blended with water proofing compound properly.
(iii) Rough Kota Stone 22 to 25 mm Thick
The stone slabs to be used for this item shall be in thickness of 22 mm to 25 mm. Larger
size of stone slabs i.e. 550 mm x 550 mm or 550 mm x 850 mm shall be used to minimise the
number of joints.
General requirement of Kota stone shall be as laid down in CPWD Specifications of Kota
Stone flooring.

(iv) Preparation of Cement Slurry
Cement slurry shall be prepared by using 2.2 kg of blended cement per sqm. area. Each
time only that much quantity shall be prepared which can be covered on the surface and
the surface in turn would be covered with 25 mm thick cement mortar base within half an
hour. Slurry prepared and remained unused for more than half an hour shall be totally
rejected.
(v) Preparation of Cement Mortar
Cement mortar 1:3 (1 blended cement: 3 coarse sand) shall be prepared with cement/
water duly blended as explained in clause 22.1.1 (ii). Only that much quantity of cement
mortar which can be consumed within half an hour, shall be prepared. Any cement mortar
that is prepared and remains unused for more than half an hour shall not be used in the
work and shall be rejected.
(vi) Laying Water Proofing Course
Before laying the base course of cement mortar 1:3, the lean concrete surface shall be
cleaned neatly with water. Cement slurry prepared as per clause 22.1.1 (ii), shall be applied
only on the area of the concrete surface, that can be covered with the cement mortar (1:3)
base course within half an hour. The cement slurry should cover every spot of the surface
and no place shall remain uncovered. Just after the application of cement slurry on the
surface, the cement mortar prepared as per clause 22.1.1 (v) should be used for laying the
base course. Base Course should be laid to a perfect level with wooden/aluminium straight
edge of at least 2 mtrs. long. The top surface of cement mortar should be finished neatly
and later scratched when green with a suitable instrument before the base course dries
and gets hard that is just before the base course takes up initial set.
When the 25 mm thick base course is just getting set the cement slurry prepared as per
clause 22.1.1 (iv) should be spread over the base course upto the area that shall be
covered with just two to three stone slabs. The cement slurry shall be spread in such a way
that the area of base course to be covered immediately shall be covered with slurry without
any gap or dry spots. Immediately on applying cement slurry on the base course the Rough
Kota Stone slab shall be laid over the base course and pressed gently so that the air gap
can be removed. The slurry applied on the surface which gets spread when the stone slab
is pressed shall get accumulated in the joints of adjacent stone slabs and if any gap still
remains between the stone slabs the same should also be filled with additional quantity of
cement slurry. For laying the stone slabs in perfect level, two stone slabs at adjacent
concerns/ends shall be fixed firmly to the required level and a string stretched over the two
slabs, the intermediate slabs shall then be set to the level of the string.
After filling all the joints of the Rough Kota stone Slabs with cement slurry the area of stone
slab shall be laid with cement mortar 1:3. The surface of stone slabs shall be cleaned and
lightly watered. Cement mortar 1: 3 prepared as per clause 22.1.1 (iv) shall be used for
laying this course. For laying this course 25 mm high wooden strips shall be used and the
top surface shall be finished smooth without using additional cement or slurry.
After laying 3rd course and before the mortar layer takes the initial set, Stone aggregate of
10 mm to 12 mm nominal size shall be uniformly spread and lightly pressed into the finished
surface @ 8 cudm./sqm. The aggregates shall not be embedded totally inside the mortar
and shall be visible on the top surface.
In cases where slope is to be provided for the water proofing layer, grading with additional
cement concrete/cement mortar shall be provided and then the water proofing layer shall
be laid on the graded surface. Extra payment shall however be made for the grading course.

(vii) Curing
Immediately after completing the fourth layer, arrangements shall be made for the top RCC
slab as quickly as possible and in the mean time till the top slab is casted the water proofing
treatment shall be kept wet continuously. In case the concreting of slab gets delayed for
more than 2 weeks the curing can be stopped after 14 days.
(viii) Measurement
Length and breadth shall be measured along the finished surface correct to a cm and the
area shall be worked out to nearest 0.01 sqm.
(ix) Rate
The rate shall include the cost of all labour & materials involved in all the operations described
above. The cost of grading with cement concrete / cement mortar shall be paid for separately.
22.1.2 Water Proofing of Internal Horizontal Surfaces of Under- ground Structure (Fig. 22.2)
Same as in 22.1.1 above except that water proofing courses will be laid on R.C.C. Slab.
22.2 INTEGRAL CEMENT BASED WATER PROOFING TREATMENT ON THE VERTICAL SURFACE
OF UNDER GROUND STRUCTURES (FIG. 22.3)
(i) Preparing the Surface
The surface of the structure to be treated shall be roughed either by raking of joints in case
of brick/ stone masonry or by hacking the cement concrete surface with a specifically made
hacking tool just after removing shuttering. Alternately, the surface should be roughened
by providing spatter dash key as explained under clause 22.1.1 (i). While doing water
proofing to vertical faces from inside, it shall be ensured that water proofing treatment of
floor slab is not damaged. Preferably, water proofing of vertical surface shall be done
before that of horizontal surface.
(ii) Blending Cement/Water with Water Proofing Compound Same as under clause 22.1.1(ii).
(iii) Rough Kota Stone Slab
Same as explained under clause 22.1.1(iii).
(iv) Preparation of Cement Slurry
Same as explained under clause 22.1.1(iv).
(v) Preparation of Cement Mortar
Same as explained under clause 22.1.1(v).
(vi) Laying Water Proofing Course
Same as explained under clause 22.1.1(vi). Further rough kota stone are not sufficiently
rough to remain in vertical position held by cement slurry. Therefore, the grip for the stone
slab has to be increased and this can be done by planting 12 mm to 15 mm nominal size
stone aggregate fixed with araldite on surface of each sand stone slab.
(vii) Curing
Same as explained under clause 22.1.1(vii). Further till the water proofing work on vertical
face is in progress, the water proofing work done on floor slab shall be kept wet for a
minimum period of 14 days. Immediately after completion of water proofing on vertical
faces of side walls, the water tank shall be gradually filled with water for testing.
(viii) Measurement
Same as explained under clause 22.1.1(viii).
(ix) Rate
Same as explained under clause 22.1.1(ix).

22.3 WATER PROOFING TREATMENT TO VERTICAL AND HORIZONTAL SURFACE OF
DEPRESSED PORTION OF WC, KITCHEN AND THE LIKE
22.3.1 Before the Water Proofing Treatment

Before the water proofing treatment, the internal plaster of ceiling and walls of WC block leaving
the portion for dado/skirting should be completed. Grooving / chasing for doing the concealed work
of GI/CI pipes/Electrical conduits should be completed. Cleaning the depressed/sunken portion of
WC of all debris, extra mortar sticking to the vertical and horizontal surface etc. Necessary holes for
‘P’ trap /Nhani trap/Water escape pipe etc should be completed.
22.3.2 Preparing Surface and Fixing Pipes and Fittings

Before the water proofing treatment work, proper key in the concrete surface should be provided.
The depressed/sunken portion should be hacked by a hacking tool, after the concrete slab is cast
and when this concrete is still green.
The vertical surfaces of the depressed /sunken portion should be hacked with a hacking tool just
after the shuttering is removed.
In case of old work, the water proofing treatment on such surfaces shall be permitted after making
proper spatter dash key.
Fixing the ‘P’ trap in position and all other pipes work including the water escape pipe shall be
fixed properly and the holes should be plugged carefully before taking up the water proofing work.
22.3.3 1st Course

Cement duly blended with water proofing compound as explained in clause 22.1 shall be used for
preparing the cement slurry.
The consistency of the slurry should be such that 4.4 kg. of blended cement with water proofing
compound is used per sq. metre area of surface to be treated. The slurry should be started from the
vertical faces towards the bottom of the floor as shown in Fig. 22.4. Particular care should be taken
to see that the slurry is applied to corners without leaving any gap.
22.3.4 2nd Course

Immediately on applying the blended cement slurry on the surface to be treated cement plaster
20 mm thick in CM 1:3 (1 blended cement: 3 coarse sand) shall be applied both on vertical and
horizontal surfaces taking particular care to complete the entire depressed/ sunken portion of WC
within a day so that the plaster can be done without any joint. Junctions shall be properly rounded.
The surfaces of the plaster shall be left rough but finished in one plain and cured for a week.
On completion of the curing period both horizontal and vertical surfaces shall be cleaned properly
and gently and allowed to dry.
22.3.5 3rd Course

Only after the surface is completely dried the blown or residual bitumen shall be applied @
1.7 kg. of bitumen per sqm area.
22.3.6 4th Course

PVC sheet 400 micron thick shall be spread evenly without any kink immediately, so that the PVC
sheet sticks to the surface firmly. PVC sheet shall be continued to be laid over the main slab upto
100 mm.

Overlapping of PVC sheet should be done with a minimum overlap of 100 mm, duly pasting the
overlapped sheet with an application of bitumen @ 1.7 kg./ sqm.
The projections of pipes and ‘P’ trap outlet etc. inside the depressed/sunken portion of WC shall
also be cladded with water proofing treatment layer upto a height of 150 mm, using a coat of bitumen
with PVC sheet complete.
The surfaces of depressed/sunken portion of WC shall not be left without covering with specified
filling material and base concrete, otherwise the PVC sheet layer may be tampered by the labour
working in the vicinity.
Fixing up of WC pan, filling specified material and the top base concrete should be done as early
as possible and the top horizontal layer of water proofing may be taken up later i.e. just before laying
the floor tiles.
22.3.7 Measurement
Length and breadth shall be measured along the finished surface correct to a cm. and area shall
be worked out to nearest 0.01 sqm. No payment however shall be made for the 100 mm overlap of
PVC Sheet over the roof slab.
22.3.8 Rate
The rate shall include the cost of labour and materials involved in all operations described above.
22.4 PROVIDING WATER STOPS

22.4.1 Water stops conforming to IS 12200 for construction/expansion joints should be fabrication
from a plastic compound, the basic resin of which shall be polyvinyl chloride. The compound shall
contain additional resin/ plasticizer inhibitors or other materials such that when the materials is
compounded it shall meet the requirement given in IS 15058.
22.4.2 Type of Joints for which Water Bars are Provided

The water bars are provided only for the movement of joints in a water retaining structure.
Different types of movement joints are as described below:
Complete Contraction Joint: This is a movement joint with deliberate discontinuity both in concrete
as well as the reinforcement but no initial gap is maintained between the concrete on either side of
the joint. This joint is intended to accommodate the contraction of the concrete.
Partial Contraction Joint: This is a movement joint with deliberate discontinuity in concrete but no
water bar is provided and no discontinuity is provided in steel. No initial gap is maintained between
the concrete on either side of joint.
Expansion Joint: This is also a movement joint with complete discontinuity in both reinforcement
and concrete. It is intended to accommodate either expansion or contraction of the structure.
In general such joint requires the provision of an initial gap between the adjoining parts of the
structure which accommodates expansion or contraction of the structure.
22.4.3 Types and Performance of Water Bars

Water bars are performed strips of impermeable material which are embedded in the concrete
during construction so as to span across the joints and provide a permanent water tight seal during
the whole range of joint movement.

The most usual form of water bars are strip with a longitudinal corrugation as shown in Fig. 22.5.
Another form of water bar of metallic type is Z shaped strip.
Water bars of copper, sheet lead, natural or synthetic rubber and plastic such as polyvinyl chloride
(PVC) are also used. These bars comprise of central longitudinal hollow tube with thin walls and stiff
wings of about 150 mm width.
Out of the metals available copper is most suitable as regards ductility, resistance to corrosion in
air, water and concrete. However, it may be attacked by some wastes. If sheet lead is used it should
be insulated from concrete by a good coat of bituminous or suitable composition. Natural synthetic
rubber and plastics have very considerable advantage in handling, splicing and in making intersections.
Galvanized iron sheets may also be used with the specific permission of the Engineer-in-charge
provided the liquid stored or the atmosphere around the liquid retaining structure is not excessively
corrosive i.e. sewage.
The strip water bars described as above, while placing in position has to be passed through the
end shutter of the first placed concrete with the result the shuttering at this point should be perfectly
water tight otherwise cement slurry may escape from the concrete being laid and will ultimately weaken
the structure. Therefore to avoid the above problem one can prefer moulded type of water bar.
The design of the moulded water bar with several projections need to be passed through the end
shutter while placing the same in position. Another main advantage of this water bar is that since it
occupies bigger proportion of the thickness of the joint it would lengthen the shortest alternative
water path through the concrete.
22. 4.4 It is important to ensure proper compaction of concrete around the water bar. Proper cover to
all the reinforcement shall be maintained. Sometimes to increase the bond the holes are provided in
the copper water bars but in the long run it proves to be disadvantageous as it shortens the path of
water through concrete. Water bars should be placed at the centre of the wall or if it is to be provided
away from the centre its distance from either face of the wall shall not be less than half of the width of
water bar or as specified/directed by the Engineer-in-charge.
22.4.5 Covers Plates for Joint

Sometimes joint cover plates have to be used for expansion joints mainly to avoid the risk of a
fault in the water bar which is embedded. The plates to be used should be either copper or sheet
lead. In case the copper plates are to be used, it should be clamped to the concrete face on each
side of the joint. To ensure water tightness suitable gasket shall be used. Joint cover plates of sheet
lead are also used and fixed on the joints. In this case the edges may return into grooves formed in
the concrete and can be made completely water tight by lead caulking. Faces of the concrete to
which sheet lead is to be fixed should be painted with bituminous or other suitable composition and
the lead sheet should be similarly coated before fixing.
22.4.6 Spacing of Joints

In Reinforced Concrete floors movement joints should be spaced at not more than 7.5 m apart in
two directions at right angles. The wall and floor joints should occur at the base of the wall in which
case corresponding vertical joint is not important.
In concrete walls, the vertical movement joints should normally be placed at a maximum spacing
of 0.75 m in reinforced walls. The maximum length desirable between vertical movement joints will
depend upon the tensile strength of the walls and may be increased by suitable reinforcements.

Amongst the movement joints in floors and walls as mentioned above, expansion joint should be
normally be provided at spacing of not more than 30 m between successive expansion joints or between
the end of the structure and the next expansion joint, all other joints being of the contraction type.
In case of expansion joints the filling of these with bitumen filler, bitumen felt or any such material
etc. shall be paid for separately in running metre. The measurement shall be taken upto two places
of decimal stating the depth and width of joint.
In case joint cover plates either of copper or sheet lead with ancillaries are provided, these shall
be measured and paid for separately.
22.4.7 Measurement
Length shall be measured correct to a cm and net quantities shall be calculated upto two places
of decimal.
Each category of water stops/bar such as PVC, copper specifying width, thickness shall be
measured and paid for separately.
22.4.8 Rate
The rate shall include all labour and materials in all the operations described above.
22.5 WATER PROOFING TREATMENT IN SUNKEN PORTION OF WCs, BATHROOMS ETC.

22.5.1 Preliminaries to be Attended
The preliminaries shall be attended as described in clause 22.3.1.
22.5.2 Preparing Surface, Fixing Pipes and Fittings

In this case, unlike as described in clause 22.3.2, no hacking of surface need be made, but only
extra mortar sticking to the surface should be removed and the surface should be cleaned thoroughly.
Fixing ‘P’ trap etc. shall be done as described in Clause 22.3.2.
22.5.3 Providing and Laying of Slurry for First Layer

The consistency of the slurry should be such as to cover the desired area by using 0.488 kg of
blended cement per sqm of area.
On deciding the correct quantity of water required per sqm. area the required quantity of slurry
should be prepared which can be applied over the desired surface within half an hour of mixing with
0.488 kg. of grey cement + 0.253 kg. water proofing compound as per manufacturer specifications +
x litres of water per sqm. area and the required quantity of slurry thus prepared should only be used
for first application.
The first layer shall be applied with painting brushes over the specified and dampened area
carefully including the corners, holes on the surfaces and joints of pipes in concrete etc. and the
application should continue at least upto 150 mm height of fixtures of pipes from the surface. The
surface on application shall be air cured for 4 hours.
22.5.4 Providing and Laying of Slurry for Second Layer

The quantity of slurry required for second application to be covered within an hour of mixing
shall be prepared with 0.242 kg. cement + 0.126 kg. water proofing compound + y litres of water per
sqm. area and the required quantity of slurry thus prepared should only be used for second
application.
The application of 2nd layer of slurry is same as for first layer as detailed in clause 22.5.3.

The applied surface shall be allowed to air cure for 4 hours and thereafter water curing shall be
done for full 48 hours.
In case no further work as described above is to be taken up immediately on completion of water

proofing treatment due to any reason it is recommended to protect the treated portion with cement
plaster 1:4 as a protective layer for which separate payment shall be made to the contractor.
22.5.5 Measurement
Length and breadth shall be measured along the finished surface correct to a cm and area shall
be worked out to nearest 0.01 sqm.
22.5.6 Rate
above. The cost of plastering shall be measured and paid for separately.
22.6 WATER PROOFING TREATMENT ON ROOF SLABS

22.6.1 Before taking up the water proofing work the construction of parapet walls, including finishing
should be completed. Similarly, the ancillary items like haunches, khurras, grooves to tack the fibre
cloth layer, fixing up of all down take pipes, water pipes and electric conduits etc. should be completed
and no such work should be allowed on the area to be treated during the progress of water proofing
treatment or even later.
22.6.2 Preparing Surface

There is no necessity of hacking the surface but the surface to be treated shall be cleaned
including removing the mortar dropping from the surface.
22.6.3 Providing and Laying of Cement Slurry

The procedure to prepare and apply the cement slurry shall be same as detailed in clause 22.5.3
except that over projected pipes etc. slurry shall be applied just upto 100 mm height instead of 150
mm height. The slurry shall be applied upto a height of 300 mm on parapet walls and in the groove
where the fibre glass cloth is to be tucked.
22.6.4 Providing and Laying of Fibre Glass Cloth (2nd Layer)

The fibre glass cloth shall be of approved brand and shall be thin, flexible uniformly bonded mat
composed of chemically resistant borosilicate glass fibre distributed in random open porous structure
bonded together with a thermosetting resin.
Immediately on applying the slurry on a sufficiently workable area as detailed above in clause
22.6.3 when the slurry applied is still green the fibre glass as specified shall be spread evenly on the
surface without any kink and pressed in such a way that no air spaces exist. The fibre glass cloth
shall be taken upto a height of 30 cm on parapet walls and tucked in the groove specially prepared
at that height.
A minimum overlap of 100 mm width shall be provided when the fibre cloth has to be joined. The
joining of 100 mm overlap shall be done with the same slurry used for the application on surface as
first layer. The fibre cloth shall also be extended upto a height of 100 mm over pipes projecting from
the surface.
22.6.5 Providing and Laying of Cement Slurry for Third Layer

The quantity of water required to prepare slurry which can cover one sqm. area of the surface to
be treated shall be calculated as described in clause 22.5.3 and consider this quantity as say x
litres/sqm.

On deciding the correct quantity of water required, the slurry shall be prepared by mixing 1.289
kg/m2 of grey cement + 0.67 kg./sqm. of Water Proofing Compound +1.289 kg./sqm. of coarse
sand + x litres of water. Slurry shall be prepared for the area to be covered within half an hour of
mixing.
The consistency of the slurry shall be such that in one application with a brush 1.5 mm thickness
of slurry can be coated on the fibre glass cloth surface.
This slurry shall be applied evenly on the entire surface covered with fibre glass cloth so that a
layer of 1.50 mm thickness of slurry is formed.
The application of slurry shall be continued over the 300 mm portion of parapet wall and also
the portion tucked in the groove on top.
The entire surface shall be allowed for air curing for 4 hours and later the surface shall be cured
with clean water for 7 days.
On completion of curing the grooves where the fibre glass cloth is tucked shall be closed neatly
with cement mortar mixed with water proofing compound and the repaired surface should be cured
by clean water for 7 days.
Fourth and final layer of brick tiling if required shall be laid and paid for separately.
22.6.6 Measurement
Length and breadth shall be measured along the finished surface correct to a cm and area shall
be worked out to nearest 0.01 sqm. Overlaps and tucking in a flashing grooves shall not be measured.
No deductions shall be made for openings or recess or chimney stack, roof lights or Khurras of area
upto 0.40 sqm, nor anything extra shall be paid for forming such openings, recess etc. For area
exceeding 0.40 sqm. deduction will be made in the measurement for the full opening and nothing
extra shall be paid for making such opening.
22.6.7 Rate
The rate shall include the cost of labour and material involved in all the operations described
above, however the cost of brick layer with cement mortar shall be paid for separately.
22.7 INTEGRAL CEMENT BASED WATER PROOFING TREATMENT WITH BRICK BAT COBA (Fig. 22.6)
22.7.1 Before taking up the work the preliminaries to be attended shall be exactly same as described
in clause 22.6.1.
22.7.2 Preparing the Surface

The surface of the slab should be roughened by scrapping when the slab concrete is still green,
however, the surface need not be hacked. In case the slab is already cast and surface fairly finished,
the same shall be cleaned neatly of all mortar droppings, loose materials etc with brooms/cloth.
22.7.3 Providing and Laying of Slurry under Base Coat

The quantity of water required to prepare the slurry with 2.75 kg. of blended cement to be painted
over an area of 1 sqm. shall be calculated exactly as described in clause 22.5.3.
Depending upon the area of surface that has to be covered, the required quantity of slurry
should be prepared using 2.75 kg. blended cement + water per sqm. area to be covered, taking
particular care to see that only that much quantity of slurry shall be prepared which can be used
within half an hour of preparation i.e. before the initial setting time of cement.

The prepared slurry shall be applied over the dampened surface with brushes very carefully,
including the joints between the floor slab and the parapet wall, holes on the surfaces, joints of
pipes, masonry/concrete etc.
The application of the slurry should continue upto a height of 300 mm on the parapet wall and
also the groove as shown in Fig. 22.6. The slurry should also be applied upto a height of 150 mm
over pipe projections etc.
22.7.4 Laying Base Coat 20 mm thick

Immediately after the application of slurry and when the application is still green, 20 mm thick
cement plaster as base coat with cement mortar 1:5 (1 blended cement : 5 coarse sand) shall be
evenly applied over the concrete surface taking particular care to see that all the corners and joints
are properly packed and the application of the base coat shall be continued upto a height of 300 mm
over the parapet wall.
22.7.5 Laying Brick Bat Coba

Brick bat of size 25 mm to 115 mm out of well burnt bricks shall be used for the purpose of brick
bat coba.
The brick bats shall be properly dampened for six hours before laying.
Brick bats shall be laid to required slope/gradient over the base coat of mortar leaving 15-25 mm
gap between two bats. Cement mortar 1:5 (1 blended cement: 5 coarse sand) shall be poured over
the brick bats and joints filled properly. Under no circumstances dry brick bats should be laid over
the base coat.
The haunches/gola at the junction of parapet wall and the roof shall be formed only with brick bat
coba as shown in Fig. 22.6.
In case the brick bat coba is laid on the base coat immediately on initial set there will be no
necessity of applying cement slurry over the base coat before laying the brick bat coba. However, if
the brick bat coba is to be laid on the subsequent day, cement slurry prepared as described in
clause 22.7.3 shall be applied over the top surface of the base coat, then only the brick bat coba
shall be laid.
22.7.6 Application of Slurry over Brick Bat Coba

After two days of curing of brick bat coba cement slurry prepared as per clause 22.7.3 shall be
applied on the surface of brick bat coba The application of slurry shall be the same as described in
clause 22.5.3 which should cover the haunches/gola, and the remaining small portion of parapet
wall and also inside the groove as shown in the figure.
22.7.7 Laying Finishing Layer (Protective Coat)

Immediately on applying the cement slurry over the surface of the brick bat coba and when the
slurry applied is still green, the fibre glass cloth as specified in clause 22.6.4 shall be spread evenly
on the surface without any kink & pressed to see that no air spaces exist. The fibre glass cloth shall
be taken up to a height of 300 mm on parapet walls & tucked in the groove specially prepared at that
height. 20 mm thick layer of cement plaster, without leaving any joints shall be applied with cement
mortar 1:4 (1 blended cement: 4 coarse sand) over the entire fibre glass cloth including the haunches/
gola and the small portion on the parapet wall. The groove in the parapet wall over the haunches
shall also be filled neatly packing the mortar firmly in the groove.
The surface of the finishing layer (protective coat) shall be neatly finished with cement slurry
prepared as per clause 22.7.3. The finished surface shall be allowed to dry for a while and then
pattern of 300 mm x 300 mm groove, 8 mm deep shall be made over the entire surface.

22.7.8 Curing and Testing the Treatment
The entire surface thus treated shall be flooded with water by making kiaries with weak cement
mortar, for a minimum period of two weeks.
22.7.9 Measurement
The measurement shall be taken along the finished surface of treatment including the rounded
and tapered portion at junction of parapet wall. Length and breadth shall be measured correct to a
cm and area shall be worked out to nearest 0.01 sqm. No deduction in measurement shall be made
for openings or recesses or chimney stacks, roof lights or khurras of area upto 0.40 sqm., nor
anything extra shall be paid for making such openings, recesses etc. For areas exceeding 0.40
sqm., deduction will be made in the measurements for the full openings and nothing extra shall be
paid for making such openings.
22.7.10 Rate
above.
22.8 WATER PROOFING TREATMENT WITH BITUMEN FELT

22.8.0 Water proofing treatment with self finished felt shall be four courses or six courses as described
in the item. Four course water proofing treatment with self finished felt is a normal duty treatment
suitable for buildings where the cost of roof treatment is required to be restricted.
Six course water proofing treatment with self finished felt is a heavy duty treatment suitable for
important structures.
22.8.1 Materials
22.8.1.1 Self finished felt (Appendix A and B) shall conform to the type and grade given in the
description of the item. This shall be one of the following types:
(i) Type 3 grade 1 hessian base felt conforming in all respects to IS 1322.
(ii) Type 2 grade 1 fibre base bitumen felt conforming to IS 1322.
(iii) Type 2 grade 2 glass fibre base felt conforming in all respects to IS 7193.
22.8.1.2 Bonding Materials: This shall consist of blown type petroleum bitumen conforming to IS
702 or residual petroleum bitumen conforming to IS 73. The bonding material shall be so selected as
to withstand the local condition of temperature and gradient satisfactorily. The penetration of bitumen
used shall not exceed 40 in any case. Suitable residual type petroleum bitumen of penetration 30/40
(IS grade S-35), residual type petroleum bitumen with higher penetration and low softening point and
suitable blown type petroleum bitumen of IS grade 85/25 or 90/15 of approved quality shall be used.
Where proprietary brands of bonding materials are proposed to be used they shall conform in all
respects to the specifications in the preceding paras.
Sl.No Description 1st course 3rd course 5th course

kg/sqm kg/sqm kg/sqm
I. Four course treatment: 1.45 1.45 -
II. Six course treatment:
(a) With type 3 grade 1 hessian base self
finished bitumen felt. 1.45 1.20 1.45
(b) With felts other than type 3 grade 1 hessian
base. 1.45 1.20 1.70

22.8.1.3 Stone Grit and Pea- sized Gravel: Stone grit shall be 6 mm and down size. Where pea-
sized gravel is used it shall be hard, round and free from dust, dirt etc. The stone grit or pea-sized
gravel shall not be spread over vertical and sloping faces of flashings and at drain mouths. At these
places the surface shall be painted with two coats of bituminous solution.
The quantity of stone grit or pea-sized gravel required for the final course of four or six course
treatment with hessian base self finished bitumen felt type 3 grade 1 shall be 6 cubic decimeter/ sqm.

22. 8.2.1 The surface to be treated shall have a minimum slope of 1 in 120. This grading shall be
carried out with cement concrete or cement plaster with coarse sand, as per direction of Engineer-in-
charge, to the average thickness required and finished smooth. Such grading shall be paid for
separately.
22.8.2.2 Junctions between the roof and vertical faces of parapet walls, chimneys etc. shall be cased
by running triangular fillets 7.5 x 7.5 cm size, in cement concrete. At the drain mouths, the fillets shall
be suitably cut back and rounded off for easy application of water proofing treatment and easy flow
of water. Cement concrete where used shall be 1:2:4 mix (1 cement: 2 coarse sand : 4 graded stone
aggregate 20 mm nominal size). The provision of fillets shall be deemed to be covered by the item of
water proofing and shall not be measured or paid for separately.
22.8.2.3 In existing roof where gola and drip course are provided at the junction of roof and vertical
face of parapet wall, chimney stacks etc., these shall be dressed suitably and finished smooth so as
to ensure an easy and gradual turning of the flashing. Any dismantlement or forming and finishing
smooth the junction for forming the base of the flashing shall not be measured or paid for separately
and shall be deemed to form part of the preparation of the surface in the water proofing treatment.
22.8.2.4 While the grading of roof surface is being done, it shall be ensured that the outlet drain pipe
have been fixed and mouth at the entrance have been eased and rounded off properly for easy flow
of water.
22.8.2.5 When any pipe passes through the roof to be treated, angular fillet of shape shown in Fig.
22.7 shall be built around it for the water proofing treatment to be taken over it. These fillets shall not
be measured or paid for separately.
22.8.2.6 For carrying over and tucking in the water proofing felts into the parapet walls, chimney
stacks etc. a horizontal groove 6.5 cm deep, 7.5 cm wide section with its lower edge at not less than
15 cm above the graded roof surface shall be left on the inner face of the same during construction
if possible. When such groove has not been left, the same shall be cut out neatly and the base at
rear of the groove shall be finished smooth with cement plaster 1:4 (1 cement: 4 coarse sand). Such
cutting of the groove and its finishing smooth shall be deemed to be part of the water proofing item
and shall not be measured or paid for separately. No deduction shall be made either for not making
the groove or when the later has already been left in the masonry by the construction agency.
22.8.2.7 Tucking in the water proofing felt will be required where the parapet wall exceeds 45 cm in
the height from the graded surface. Where the height is 45 cm or less, no groove will be required as
the water proofing treatment will be carried over the top of the parapet wall to its full thickness. In the
case of low dividing walls of height 30 cm or less, outlets therein shall be cut open for full height and
the bottom and sides shall be rendered smooth and corners rounded and such treatment shall not
be measured and paid for separately.

22.8.2.8 Where expansion joints are left in the slab, the provision of dwarf walls and/or RCC slabs for
covering them and finishing the surface smooth shall be the responsibility of the construction agency,
which had laid the roof slab and will not be included the operation of water proofing.
22.8.2.9 The graded surface of the roof and concrete fillets and the faces of walls shall be thoroughly
cleaned with wire brushes and all loose scales etc. removed. The surface shall then be dusted off.
Any crack in the roof shall be cut to ‘V’ section, cleaned and filled up flush with cement mortar slurry
1:4 (1 cement: 4 coarse sand) or blown type petroleum bitumen of IS grade 85/25, or approved
quality conforming to IS 702. Such cleaning of the surface or treating the cracks shall not be paid for
separately.
22.8.3 Priming Coat

Where so specified, or required by the Engineer- in-Charge for example under slightly damp
conditions a priming coat consisting of a bitumen primer conforming to IS 3384 should be applied
with brush on the roof and wall surface at 0.24 litres per sqm to assist adhesion of the bonding
material (i.e. bitumen).
Such application of primer shall be paid for separately, unless specifically included in the water
proofing item.
22.8.4 Underlay
Where a floating treatment of water proofing with self finished bitumen felt is required i.e. where
water proofing treatment is required to be isolated from the roof structure, a layer of bitumen saturated
felt (underlay) shall be spread over the roof surface and tucked into the flashing groove. No bonding
material shall be used below the underlay in order to keep the underlay free of the structure. The
adjoining strips of the underlay shall overlap to a minimum of 7.5 cm at sides and 10 cm at ends. The
overlaps shall be sealed with the same bonding material as used for the self finished felt treatment.
Unless specifically included in the water proofing item, the underlay treatment shall be paid for
separately.
The underlay shall be of type 1 saturated felt conforming to IS 1322 in all respects and having a
total minimum weight of the finished bitumen felt in dry condition with mica dusting powder @ 6.8 kg
per 10 sqm. The roll shall not be damaged or crack on being unrolled on a fairly smooth and flat
surface.
22.8.5 Treatment
22. 8.5.1 The water proofing shall consist of a four or six course treatment, as given in the description
of the item, each layer of bonding materials, self finished bitumen felt or stone grit or pea sized gravel
being counted as a course.
22.8.5.2 The choice of a four or six course treatment will depend on the climatic condition, the
importance of the building, the durability required, cost and other relevant considerations.
22.8.5.3 A four course treatment shall consist of the following layers:

(a) Initial layer of bonding material applied hot at specified weight per unit area.
(b) 2nd layer of self finished bitumen felt conforming to the type and grade given in the
description of the item.
(c) Third layer of bonding material.
(d) Final layer of stone grit of pea sized gravel spread at specified volume of material per unit
area.

22.8.5.4 In a six course treatment, the first, second and third layer shall be of the same as in the four
course treatment. The fourth and fifth layer shall consist of self finished felt and bonding material
respectively. The sixth layer shall consist of stone grit or pea sized gravel.
22.8.5.5 The primer or underlay where required to be provided shall not count against the number of
courses specified.
22.8.6 Laying
22.8.6.1 Bitumen bonding material of required grade shall be heated to the working temperature
specified for the particular grade by the bitumen manufacturers and conveyed to the roof in buckets
or pouring canes in weighed quantities.
Suitable working temperature for different grades of bitumen are as under:

(i) Blown type petroleum bitumen of IS grade 85/25 or 90/15 - 180 degree C.
(ii) Residual type petroleum bitumen of penetration 30/40 - 180 degree to 190 degree C (IS
grade S-35).
22.8.6.2 Drain outlets shall be given a four or six course treatment as specified for the roof in the
description of the item in the manner specified for the flat roof surface. Water proofing treatment
shall be carried into the drain pipe or outlets by at least 10 cm. The water proofing treatment laid on
the roof surface shall overlap the upper edge of the water proofing treatment in the drain outlets by
at least 10 cm.
22.8.6.3 The self finished felt shall be cut to the required length, brushed clean of dusting material
and laid out flat on the roof to eliminate curls and subsequent stretching. The felt shall normally be
laid in length at right angles to the direction of the slope and laying shall be commenced at the lowest
level and worked upto crest. The felt shall not be laid in single piece of very long lengths as they are
likely to shrink; 6 to 8 m are suitable lengths. The roof surface shall be cleaned and dried before the
felt treatment is begun. Each length of felt shall be laid in position and rolled up for a distance of half
its length. The hot bonding material shall be poured on the roof across the full width of the rolled felt
as the latter is steadily rolled out and pressed down. The pouring shall be so regulated that the
correct weight of bonding material per unit area is spread uniformly over the surface. Excess bonding
material that gets squeezed out at the ends shall be levelled up as laying proceeds. When the first
half of the strip of felt has been bonded to the roof, the other half shall be rolled up and then unrolled
on the hot bonding material in the same way. Subsequent strips shall also be laid in the same
manner. Each strip shall overlap the preceeding one by at least 7.5 cm at the longitudinal edges and
10 cm at the ends. All overlaps shall be firmly bonded with hot bitumen. Streaks and trailings of
bitumen near edges of laps shall be levelled by heating the overlap with a blow lamp and levelling
down unevenness.
The third layer of bonding material in the four course treatment shall be carried out in a similar
manner after the flashing has been completed.
22.8.6.4 In a six course treatment the third and fourth layers of bonding material and self finished felt
shall be laid in the manner already described, taking care that laps in the felt are staggered from
those in the second layer. The fifth layer of bonding material shall be carried out after the flashing is
done (See Fig. 22.7).
22.8.6.5 High Parapet Walls, Chimney Stacks etc.: Felts shall be laid as flashings wherever junctions
of vertical and horizontal surfaces occur. Longitudinal laps shall be 10 cm. The lower layer of flashing
felt in a six course treatment shall overlap the roof water proofing by not less than 20 cm while the
upper layer shall overlap the roofing felt by 10 cm. The minimum overlap of the flashing felt in four
course specification over the roofing felt shall be 10 cm.

The flashing shall consist of the same four or six course treatment as for the roof except that the
final course of stone grit or pea-sized gravel shall be replaced by an application of bituminous solution
of approved quality in two coats on the vertical and sloping faces only, of the flashing. The overlap
along the length of flashing shall stagger with those in the second layer of flashing felt (in a six
course treatment and with the joints in the roof felt).
The upper edge of the flashing felt shall be well tucked into the flashing grooves in the parapet,
chimney stacks etc. to a depth of not less than 6.5 cm. Corresponding applications of bonding
material shall also be made. The flashing treatment shall be firmly held in place in the grooves with
wood edges at intervals and the grooves shall be filled up with cement mortar 1:4 (1 cement: 4
coarse sand) or cement concrete 1:2:4 (1 cement : 2 coarse sand : 4 graded stone aggregate 6
mm nominal size) and surface finished smooth with the rest of the wall. The cement work shall be
cured for 7 days. When dry, the exposed plaster joints of grooves shall be painted with bitumen
and two coats of bituminous solution shall be applied on the vertical and sloping surface of flashing
(see Fig. 22.7).
After the top flashing felt layer has been fixed, the penultimate layer of bonding material shall be
applied over the roofing felt and the horizontal overlaps and vertical and sloping surfaces of the
flashings at the specified rate. Stone grit or pea sized gravel shall then be spread uniformly over the
hot bonding material on the horizontal roof surface at the specified quantity per unit area and pressed
into it with a wooden roller.
22.8.6.6 Low Parapet Walls: Where parapet walls are of height 45 cm or less, bitumen felt flashings
shall be provided in the same manner as for flashings in the case of high parapet walls except that
the upper edge shall be carried upto the full height of the wall and taken right across the top of the
parapet and down on the external vertical faces to a minimum distance of 5 cm (see Fig. 22.7).
22.8.6.7 Low Dividing Walls: Where low dividing walls or inverted beams are met with, the same
shall be covered with a four or six layer treatment as for the main roof, the latter bearing carried down
both sides of the wall and overlapping the roofing treatment as in the case of flashing of high parapet
walls (see Fig. 22.7).
Drain outlets where formed in the low dividing walls, shall be given water proofing treatment of
the same number of courses as specified for the flat roof surface. The bottom and sides shall be so
treated that all overlaps are in the direction of flow of drainage.
22.8.6.8 Expansion Joints: Where the expansion joints are provided in the slabs, the joints and
their cover slabs shall be suitably treated with water proofing. A typical sketch of an expansion joint
with the RCC slabs on either side of the joint turned vertically up and covered with precast RCC
cover slabs as given in Fig. 22.7. The cover slabs shall cover the vertical turned up dwarf walls by
not less than 7.5 cm and are provided with throatings on their underside along their length. The
water proofing treatment shall be taken up the sloping junction fillets and the vertical faces of the
walls to the underside of the cover slabs. The cover slabs are given the water proofing treatment like
the roof slabs, after the cross joints between adjacent cover slabs are first sealed with 15 cm width of
roofing felt struck to them with bitumen. The water proofing treatment shall be carried down the sides
of the cover slabs to their full thickness. Care shall be taken to see that overlaps if any in the roofing
over the cover slabs stagger with the joints between cover slabs.
The formation of the expansion joints and provision of cover slabs shall be the responsibility of
the construction agency. The formation of the junction fillets and the water proofing treatment of the
joint and cover slabs shall be carried out by the water proofing agency. No extra shall be paid for the
junction fillers or for the sealing of the cross joints in the cover slab with 15 cm width of bitumen strips.

22. 8.6.9 Pipes: Where vertical pipe outlets are met with 7.5 x 7.5 cm fillets of lime or cement concrete
of the type and section shown in Fig. 22.7 shall be provided and flashing of four or six course
treatment, same as for the roofing treatment shall be laid.
The upper edge of the flashing shall be laid sloping down forward and butted against the pipe
and annular depression so formed shall be filled with hot bitumen. A circular metal collar in the shape
of an inverted truncated cone shall be fixed on the pipe to throw off the rain water clear of the
flashing and this shall be paid for separately.
22.8.6.10 Terrace: Where roof surfaces are expected to be used precast cement concrete tiles or
40 mm thick cement concrete shall be laid on the water proofing treatment. In such cases, the final
course of stone grit or pea sized gravel shall not be laid in the water proofing treatment. Suitable
adjustment in the rates will be effected for not providing the stone grit or pea sized gravel layer.
Cement concrete in situ flooring shall be laid in panel not exceeding 0.4 square metres each. Precast
tiles or in situ concrete flooring where laid shall be paid for separately unless included in the description
of the water proofing item.
22.8.7 Measurements
22.8.7.1 Length and breadth shall be measured correct to a cm. The area shall be calculated in
square metres correct to two places of decimal.
22.8.7.2 Measurements shall be taken over the entire exposed area of roofing and flashing treatment
including flashing over low parapet walls, low dividing walls and expansion joints and at pipe projections
etc. Overlaps and tucking into flashing grooves shall not be measured.
22.8.7.3 Vertical and sloping surfaces of water proofing treatment shall also be measured under the
four or six course treatment as the case may be, irrespective of the fact that the final course of grit or
pea sized gravel is replaced by bitumen primer.
22.8.7.4 Primer or saturated felt underlay, where provided, shall also be measured in the same
manner as the water proofing treatment and paid for separately. No deduction in measurements
shall be made for either openings or recesses for chimney stacks, roof lights and the like, for areas
upto 40 square decimetre (0.4 sqm) nor anything shall be paid for forming such openings.
For similar areas exceeding 40 sq. decimetre deductions will be made in measurements for full
opening and nothing extra shall be paid for forming such openings.
22.8.8 Rate
above and the particular specifications given under the different items, with the corrections noted in
the relevant sub-paras.
22.9 GRADING ROOF WITH CEMENT CONCRETE 1:2:4

22.9.1 Materials
Cement, coarse sand and graded stone aggregate 20 mm nominal size, shall be used as specified
in the item.
The specifications for the materials and method of preparation of concrete shall conform in general
to the specification described in sub-head 4.0 of CPWD Specifications.
22.9.1.1 Laying: Before laying cement concrete for grading, the level markings to the required
slope/gradient shall be made only with cement concrete on the surface of the slab at suitable spacing
with the help of string and steel tape (Measuring tape) so that the mason can lay the concrete to the
required thickness, slope / gradient easily in between the two level markings.

On getting the level marking approved by the Site Engineer the surface should be sprinkled with
thick cement slurry and the concrete should be laid carefully, without throwing from height, in
predetermined strips.
The concrete should be consolidated by specially made wooden tamping. After the tamping is
done the surface should be finished to required slope/gradient with wooden trowels without leaving
any spots of loose aggregates etc.
The mixed cement concrete must be laid in position, within half an hour of its mixing. In case any
quantity of concrete remains unused for more than half an hour the same should be rejected and
removed from the site.
22.9.1.2 Finishing: The slope of finished terrace shall not be more than 1 in 120 unless a steeper
slope is desired by the Engineer-in-Charge.
The minimum thickness of the concrete at its junction with Khurra or parapets shall be 5 cm. The
concrete shall be rounded at the junction of roof slab and parapet. It is desirable to provide a haunch/
gola/filler at the junction of the parapet wall and the roof slab as shown in Fig. 22.8.
The finished concrete surface shall present a smooth surface with correct slopes and uniform
rounding. The concrete should be free from cracks. Excess trowelling shall be avoided.
22.9.1.3 Thickness: Average thickness shall be as per clause 22.9.1.2 as shown in Fig. 22.8.
22.9.1.4 Curing: Curing shall be done either by spreading straw/Hessian cloth over the graded
surface, keeping the same wet for full 10 days or flooding the graded area with water by making
kiaries with weak cement mortar, for 10 days. Occasional curing by simply spraying water now and
then shall not be permitted under any circumstances.
22.9.1.5 Measurement: Length and breadth shall be measured correct to a cm. Area shall be worked
out to nearest 0.01 sqm. and the cubical contents shall be worked out to nearest 0.001 cum.
No deduction shall be made for either opening or recesses for chimney stacks, roof lights etc.,
Khurra for area upto 0.1 sqm. Nothing extra shall be paid either for any extra material or labour
involved in forming such opening or recess or in rounding the concrete function of roof with parapet
walls, chimney stack, khurra etc.
22.9.1.6 Rate: The rate shall include the cost of all the materials and labour involved in all the
operations described above.
22.10 GRADING ROOF WITH CEMENT MORTAR

22.10.1 Materials
Cement and coarse sand shall be as specified in the item of work or as described in sub-head 3.0
of CPWD Specifications.
22.10.1.1 Cement Mortar : Cement mortar 1:3 (1 cement: 3 coarse sand) /1:4(1 cement: 4 coarse
sand) specified in the item of work shall conform to the specification described in sub-head 3.0 of
CPWD Specifications.
22.10.1.2 Preparation of the Surface: The surface shall be cleaned properly with brooms bruch,
cloth to remove all dirts, dust, mortar droppings.

22.10.1.3 Laying: Same as described in clause 22.9.1.1, except that cement mortar shall be tamped with
wooden and steel trowels and surface finished with steel trowel.
22.10.1.4 Finishing
(i) The slope of finished surface shall not be more than 1 in 120 unless a steeper slope is specified in
the item of work.
(ii) The finished surface of the grading shall present a smooth surface with correct slopes and uniform
roundings wherever they are provided. The mortar surface shall be free of cracks. Excess trowelling
shall be avoided.
22.10.1.5 Thickness: The minimum thickness of cement mortar grading at the junction with khurra or
parapet wall shall be 20 mm. The cement mortar shall be rounded at the junction of roof slab and parapet.
It is desirable to provide a haunch/gola/filler at the junction of parapet wall and the roof slab. The maximum
thickness that shall be adopted for grading with cement mortar shall be 50 mm. It is not at all desirable to
lay the cement mortar grading for greater thickness and in that case it is advised to go in for grading with
Cement Concrete. The average thickness shall be as shown in Fig. 22.9 and 22.10.
22.10.1.6 Curing: Curing for the grading with cement mortar shall be done exactly as described in clause
22.9.1.4.
22.10.1.7 Measurement: Same as specified in clause 22.9.1.5.
22.10.1.8 Rate: The rate shall include the cost of all the labour and material involved in all the operations
described above.
22.11 Clause shifted to Sub Head 14 (Repairs to Buildings) as clause no. 14.49
22.14 WATER PROOFING TREATMENT WITH INTERGRAL CRYSTALINE ADMIXTURE

22.14.0 General
One method that can simplify the protective process is to make concrete with Integral Crystalline Admixtures
that reduce its permeability in effect to make the concrete itself waterproof. Apart from the regular workability
admixtures, Integral Crystalline durability admixtures shall be added to all concrete, structural and otherwise,
to waterproof & enhance the Concrete Durability. The Crystalline Admixture shall be added either at the time
of batching at the batching plant or in the drum of the transit mixer, when the concrete arrives the point of
pouring.
The concrete water proofing industry redefined their terminology a short time ago. American Concrete
Institute (ACI) 212-3R-10 “Report on Chemical Admixture for Concrete” documents devoted chapter 15 / page
46 to permeability reducing admixtures (PRA’s) that outlines PRAH & PRAN classification or differentiates
between those suitable for concrete exposed to Non Hydrostatic Conditions (PRAN) and concrete exposed to
Hydrostatic Conditions (PRAH). Besides reducing permeability some PRA’s impart other beneficial
characteristics such as reduced drying shrinkage, reduced chloride-ion penetration, improved freeze thaw
resistance and enhanced autogenous sealing.
22.14.1 Material
Integral crystalline water-proofing admixture is one part cementitious powder added to the concrete mix
at the time of batching. Integral crystalline water-proofing admixture consists of hydrophilic chemicals such
as Portland cement, very fine treated silica sand and various active, proprietary chemicals. These active
chemicals react with moisture in fresh concrete and with the by-products of cement hydration to cause a

catalytic reaction, which generates a non-soluble crystalline formation throughout the pores and capillary
tracts of the concrete. Thus, the concrete becomes permanently sealed against the penetration of water or
liquids from any direction. The concrete is also protected from deterioration due to harsh environmental
conditions. Integral crystalline water-proofing admixture is specially formulated to meet varying project and
temperature conditions. This reaction continuous over the life of the concrete serving to seal not only initial
shrinkage cracks, but also cracks that occur over time.
22.14.2 Technical Specifications / Parameters

The specifications of the materials should match or exceed the requirements as mentioned in nomenclature
of the item.
The water proofing compound used in integral crystalline water proofing treatment shall satisfy all the
requirements indicated in relevant standards or as specified in concerned relevant codes etc. and the same
shall be got tested and get approved from the Engineer-in-charge before its use at site of work.
The integral crystalline waterproofing admixtures of hydrophilic in nature shall confirm to the following
requirements:
1. Dosage as specified in the nomenclature of item or higher as recommended by manufacturer’s
specification. The material shall fulfill the requirements of American Concrete Institute Guidelines
ACI-212- 3R-10 Chapter 15 or European norms EN 934-2-T2 and fall under PRAH (Permeability
reducing Admixtures for HYDROSTATIC conditions) and shall be capable of withstanding/resistant
to 16 bar hydrostatic pressure and reduce Coefficient of Permeability of concrete by more than 90,
when compared to controlled concrete and tested as per DIN 1048 Part 5 or EN 12390-8 by carrying
out 4 cycles each of 5 bar hydrostatic pressure for 72 hours and drying for 48 hours between the
cycles. The co-efficient of Permeability calculated as per Darcy’s Formula/ Valenta equation by
incorporating penetration values obtained at the end of fourth cycle pressure.
2. The crystalline admixture shall be compatible with any other concrete admixture confirming to
ASTM C494, EN 934-2 or IS 9103.
3. The performance of the crystalline admixture must not be restricted by water-cement ratio of
concrete mix. In other words, the crystalline admixture must perform at any water-cement ratio of
the concrete mix.
4. The integral crystalline admixture shall possess CE approval as per EN934-2 and shall be procured
from CE approved manufacturing unit. It shall also possess approval certificate from any national
apex institution mandated to issue design codes. The product has no corrosion effect on reinforcement
steel according to test norm DINV18998. The maximum chloride content less than 0.1% and maximum
alkali content less than 9.3%.
5. In addition to recognizing the use of Integrate Crystalline Admixtures. ACI 212-3R-10 has also
provided some guideline in para 15.3-”Selection and Evaluation” to select the best quality PRAH’s
materials as maximum permeability reducing admixtures at maximum Hydrostatic Pressure. Para
15.3 stated that the effect of the admixture can be evaluated by testing the permeability of concrete
both directly and indirect methods. The US Army Corps of Engineers CRC C48-92 (1992) test
method is a direct measurement of concrete permeability resistance during exposure to water
under 200 psi or 13.8 bars or 1.38 MPa of hydrostatic pressure.
6. The integral crystalline admixture must reduce Chloride diffusion Co-efficient by minimum 45%
when tested as per ASTM C 1556-4 and compared with the controlled concrete, thereby prolonging
the durability & service life of the treated concrete structure.
7. The integral crystalline admixture must be capable of self-healing of cracks up to a width of 0.5mm.

8. The integral crystalline admixture performance shall not be affected by wear abrasion of the treated
concrete surface and crystalline treated concrete shall not require protection layer.
9. The integral crystalline admixture shall be non-toxic and shall confirm to NSF-61 USA or any other
similar certification from reputable international or local third party or declaration of performance
certificate supervised by a reputable European/US third party.
10. The integral crystalline admixture when used in the concrete will have no detrimental side effect
interms of Alkali Silica Reaction (ASR) and corrosion of steel reinforcement etc.
11. The manufacturer shall submit guarantee in respect of crystalline admixture performance for 10
years against any leakage.
Note: The manufacturer shall submit test certificates in respect of all above said specification/
parameters of Integral Crystalline Admixture Material from reputed National/International laboratories
as per relevant codes. To support the claim of crystal formation, national/ international test report of
scanning electrons microscopic (SEM) photographs dandified and mature crystal formation to plug
all the capillary track and pores of the concrete shall be provided.
Total quantity of Integral Crystalline Admixture Material required shall be arranged at site of work
only after obtaining the prior approval of the Engineer-in-Charge in writing. Proper account of water
proofing compound used in the work shall be maintained. It shall be ensured that the consumption
of the compound is as per specified requirements. The contractor shall associate himself with
anyone of the applicator of water proofing compound duly approved by the Engineer-in-Charge
before start of work relating to the water proofing treatment.
22.14.3 Recommended uses

Foundations/Rafts Reservoirs, Bridges and Dams
Sewage and Water Treatment Plants Secondary Containment Structures
Tunnels and Subway Systems Underground Vaults
Parking Structures Swimming Pools and water tanks
Pre-Cast, Cast-in-situ and Shotcrete Basement Retaining Walls
applications
22.14.4 Dosage
0.8% (minimum) to the weight of cement content per cubic meter of concrete or higher dosage as
recommended by the manufacturer’s specification in reinforcement cement concrete at site of work.
22.14.5 Mixing
The integral crystalline admixture shall be used @ 0.8% (minimum) to the weight of cement content per
cum of concrete or higher as recommended by the manufacturer’s specification desired to meet water proofing
and durability criteria. Integral crystalline Admixture must be added to the concrete at the time of batching at
the batching plant or in the drum of the transit mixer, when the concrete arrives the point of pouring.
The sequence of procedures for addition will vary according to the type of batch plant operation and
equipment. The mixing shall be followed as below unless & until specified otherwise. For any detailing and
mixing guidelines the manufacturer’s specifications should be followed.
22.14.5.1 Ready mix plant- Dry batch operation

Add integral crystalline admixture in powder form to the drum of the ready-mix truck under the batch plant
and add 60%- 70% of the required water, along with required aggregate. Mix the materials for 2-3 minutes to
ensure that the integral crystalline admixture is distributed evenly throughout the mix water. Add the balance
of materials to the ready-mix truck in accordance with standard batching practices.

22.14.5.2 Ready mix plant- Central mix operation
Mix integral crystalline admixture with water to form a very thin slurry (e.g. 18kg of powder mixed with
22.7 litre of water) or recommended by the manufacturers specification. Pour the required amount of material
into the drum of the ready-mix truck. The aggregate, cement, sand and water should be batched and mixed in
the plant in accordance with standard practices (taking into account the quality of water that has already been
placed in the ready-mix truck). Pour the concrete into the truck and mix for at least 5 minutes to ensure even
distribution of integral crystalline admixture throughout the concrete.
22.14.5.3 Precast batch plant

Add integral crystalline admixture to the aggregate and sand, then mix thoroughly for 2-3 minutes before
adding the cement and water. The total concrete mass should be blended using standard practices.
It is important to obtain a homogeneous mixture of integral crystalline admixture with the concrete.
Therefore dry integral crystalline admixture powder should never be mixed directly to wet concrete as this
may cause clumping and hence thorough dispersion in the concrete mix may not occur.
22.14.5.4 Setting time and strength

The setting time of concrete mix is directly affected by the chemical and physical composition of ingredients,
temperature of the concrete and prevailing climatic conditions. Retardation of set may occur when using
integral crystalline admixture. The amount of retardation will depend upon the concrete mix design and the
dosage rate of integral crystalline admixture. However, under normal conditions, integral crystalline admixture
will provide a normal set concrete. Concrete containing integral crystalline admixture may develop higher
ultimate strengths than plain concrete. Trial mixes of the concrete should be carried out under project conditions
to determine setting time and strength of the concrete.
22.14.6 Precaution / Special Consideration

When incorporating Integral Crystalline Admixture, the temperature of the concrete mix should be above
6ºC for at least 24 hours from casting.
22.14.7 Storage / Shelf Life

Integral Crystalline Admixture must be stored dry at a minimum temperature of 7º C and its self life is one
year when stored under proper conditions. The product/material should be stored under dry condition. The self
life of the integral crystalline admixture shall be treated as one year when stored under normal conditions.
22.14.8 Measurement
The quantity i.e. weight of Integral Crystalline Admixture will be measured in kilogram correct to two
places of decimal.
22.14.9 Rate
22.15 FIBRE REINFORCED ELASTOMERIC LIQUID WATER PROOFING MEMBRANE WITH RESILIENT
ACRYLIC POLYMERS
22.15.1 Material
Fibre reinforced elastomeric liquid water proofing membrane is a ready-to-use waterproofing, white product,
with high solar reflectance and Sun Reflectivity Index (SRI) of 105, for external applications. This is made from
resilient acrylic polymers and synthetic resins in water dispersion, and when dry forms a continuous, flexible
waterproofing membrane. This is resistant to all atmospheric conditions and UV rays, and guarantees long-
lasting protection for the substrate.
22.15.2 Technical Specification/ Parameters:

1. Fibre reinforced elastomeric liquid water proofing membrane with fibers in water emulsion with high
reflectance and emissivity with a solar reflectance index SRI of 105 should comply with the
requirements of EN 1504-9 (“Products and systems for protecting and repairing concrete structures:

definitions, requirements, quality control and conformity assessment. General principles for the
use of products and systems”) EN 1504-2 coating (C) principles PI, MC and IR (“Concrete surface
protection systems”).
2. This should posses a paste like consistency having highly reflective white colour.
3. This should have density of 1.35 with dry solid content of 61.4%.
4. This should have minimum tensile strength of 1.0N/mm² as per ISO 37 or ASTM D-412.
5. This should confirm to results after testing as per EN1062-11 for exposure to artificial weather
conditions.
6. The Sun Reflectivity Index when tested as per ASTM E1980 should be 105 minimum.
7. Elongation at break (% age) of 150 % minimum as per ASTM D-412.
8. Adhesion strength is more than 1.0 N/mm2 as per ASTM D-4541.
22.15.3 Applications
It is to be applied using a long-haired roller, brush or spray on any horizontal, sloping or vertical surfaces
to form a string, flexible, tack-free dry surface, suitable for occasional light foot traffic. This can with stand
normal expansion and contraction stresses caused by temperature variations due to its flexibility. This also
helps lower the working temperature of roofs and guarantees good energy performance properties of all the
layers of the roof.

All the substrates, whether they are new or old, must be sound, clean, dry and free of all traces of oil,
grease, old paint, rust, mould and nay other material which could compromise the bond. Application temperature
may be from 70C to 400C.
Concrete and in general mineral substrates must be sound and dry with no rising damp. Any loose parts
must be removed with wire brushes. All wax, water-repellent treatments, etc. must be removed from the
surface of ceramic substrates with a suitable detergent and/ or by sanding. Any hollows and gaps in the
surface must be repaired properly with appropriate material as described and instructed by the manufacturer
of this product. The tools to be used must be properly cleaned.
22.15.5 Application Procedure

All the area of operation shall be thoroughly cleaned as described in para 22.15.3 above. Mix the content
in such a manner that they are perfectly blended into a homogenous state of liquid which can be applied by
long haired roller or airless spray. The fibre reinforced elastomeric liquid water proofing membrane with resilient
acrylic polymers shall be applied on top of concrete roof in three coats @ 10.76 litre/10 sqm or more as
recommended by manufacturer specification. One coat i.e. first coat of self priming elastomeric water proofing
liquid. The material shall be diluted with water in the ratio of 3:1 (3 parts of elastomeric water proofing liquid
and 1 part of water). Wait until the first coat is completely dry and becomes slightly darker in colour. After the
first coat has dried completely apply second coat with undiluted elastomeric water proofing liquid in a cross
direction to the previous coat. After the drying of second coat completely apply the final coat of undiluted
elastomeric water proofing liquid in a direction perpendicular to previous coat. The overall dry film thickness
should not be less than 500 microns or more as specified in manufacturer specification. Protect the membrane
from rain unless it is completely dry. The overall consumption of the material should be as per nomenclature
of the item and should also adhere to the specifications detailed in the approved schedule of the manufacturer.

22.15.6 Measurement
The length and breadth/ height shall be measured in running metre correct to two places of decimal and
the area of applications should be measured in sqm correct to two places of decimal.
22.15.7 Rate
The rate shall be include the cost of all the labour and material involved in all the operations described
above.
22.16 WATER PROOFING TREATMENT WITH INTEGRAL CRYSTALINE WATER PROOFING COATING /
SLURRY
22.16.0 General
This Integral crystalline water proofing coating / slurry of hydrophilic in nature is applied to surface of
the concrete to water proof and protect the concrete in-depth. It consists of Portland cement, specially treated
quartz sand and a compound of active chemicals. Integral crystalline water proofing coating material needs
only to be mixed with water prior to application.
When integral crystalline water proofing material is applied to a concrete surface, the active chemicals
react with moisture and the by-products of cement hydration to cause a catalytic reaction that generates an
insoluble, crystalline structure. These crystals fill the pores and minor shrinkage cracks in the concrete to
prevent any further water ingress (even under pressure). However, integral crystalline water proofing material
will still allow the passage of vapor through the structure (i.e. the concrete will be able to “breathe”). Even after
the concrete has cured, integral crystalline water proofing material remains dormant in the concrete and will
reactivate in the presence of moisture to seal capillary tracts and hairline cracks.
In addition to water proofing the structure, integral crystalline water proofing slurry protects concrete
against seawater, wastewater, aggressive groundwater and many other aggressive chemical solutions. Integral
crystalline water proofing material is approved for use in contact with potable water and is therefore suitable for
use in water storage tanks, reservoirs, water treatment plants, etc.
22.16.1 Material:
This Integral crystalline water proofing material consists of Portland cement, specially treated quartz
sand and a compound of active chemicals.
The water proofing compound used in integral crystalline water proofing treatment shall satisfy all the
requirements indicated in relevant standards or as specified in concerned relevant codes etc. and the same
shall be got tested and get approved from the Engineer-in-charge before its use.
Technical Specification/ Parameters:

The integral crystalline slurry / coating material of hydrophilic in natural shall confirm to the following
requirements:
cycles. The co-efficient of Permeability calculated as per Darcy’s Formula/ Valenta equation by
2. It shall confirm to EN1504-3 (For structural repairs-R3, Compressive Strength >25MPa) supplied
from an approved manufacturing unit having CE approval confirming to EN1504-3R3.
3. The product has no corrosion effect on reinforcement steel according to test norm DINV18998. The
maximum chloride content less than 0.1%.

4. The Integral Crystalline Slurry must be capable of self-healing of cracks up to a width of 0.5mm.
5. The crystalline water proofing coating/slurry, when used in the concrete, will have no detrimental
side effects in terms of Alkali Silica Reaction (ASR), corrosion of Steel Reinforcement etc.
6. The product performance shall not be affected by wear abrasion of the treated concrete surface and
crystalline treated concrete shall not require protection layer.
7. The crystalline water proofing coating/slurry shall be non toxic and suitable for use in potable water
facilities- NSF listed as per ANSI 61 listing or DVGW-W347, Germany or equivalent and a declaration
of performance certificate supervised by a reputed European/US third party.
8. The manufacturer shall submit guarantee in respect of crystalline water proofing coating/slurry
performance for 10 years against any leakage.
Note: The manufacturer shall submit test certificates in respect of all above said specifications/
parameters of Integral Crystalline water proofing slurry material from reputed National/International
laboratories as per relevant codes.
Total quantity of the Integral Crystalline water proofing slurry material required shall be arranged at
site of work only after obtaining the prior approval of the Engineer-in-Charge in writing. The proper
account of water proofing compound used in the work shall be maintained. It shall be ensured that
the consumption of the compound is as per specified requirements. The Contractor shall associate
himself with anyone of the applicator of water proofing compound duly approved by the Engineer-in-
Charge before start of work relating to the water proofing treatment.

Foundations/Rafts Reservoirs, Bridges and Dams
Sewage and Water Treatment Plants Secondary Containment Structures
Tunnels and Subway Systems Underground Vaults
Parking Structures Swimming Pools and water tanks
Pre-Cast, Cast-in-situ and Shotcrete applications Basement Retaining Walls

All concrete to be treated with integral crystalline water proofing slurry material must be clean and have
an “open” capillary surface. Remove laitance, dirt, grease, etc. by means of high pressure water jetting, wet
sand blasting or wire brushing. Faulty concrete in the form of cracks, honeycombing, etc. must be chased
out, treated with the same material and filled flush with the mortar mixture as specified by the manufacturer.
Surface must be carefully pre-watered prior to the application of integral crystalline water proofing material.
The concrete surface must be damp but with no wet sheen on the surface.
22.16.4 Mixing
Integral crystalline water proofing slurry / coating material should be mechanically mixed with clean water
to a creamy consistency resembling to thick oil. Only that much material should be mix as can be used within
20 minutes and mixture should be stirred frequently. The mixture should not be allowed to set, it if happens,
simply re-stir to restore workability but no more water should be added to it. The ratio of integral crystalline
water proofing material with water should be as below
(i) Vertical surface: - For applying with brush the mixing ratio shall be 5 parts of integral crystalline
water proofing coating material to 2 parts of water.
(ii) Horizontal surface: - The ratio should be 3 parts of Integral Crystalline water proofing coating
material to 1 part of water. This should be applied by brush only.

The slurry mix of the Integral Crystalline water proofing slurry material shall be applied in one or two coats
as specified/ required according to work situation in the item. After preparation of surface as described in para
22.16.3, and making the surface saturated with water before application of Crystalline Slurry, then first coat of
the slurry mix shall be applied by the brush or appropriate power spray equipment. The second coat as
specified shall be applied while the first coat is still green.
The other method of application known as dry powder consistency can also be applied on horizontal
surfaces only. The specified amount of integral crystalline water proofing material is distributed in powder form
through a sieve or a semi mechanical barrow spreader and troweled into the freshly placed concrete as this
reaches the initial set.
The integral crystalline water proofing material to be used shall be as following:-

(i) Vertical surface: - Two coats of integral crystalline water proofing material slurry coat shall be
applied @ of 0.70 kg per sqm. per coat or more as specified by the manufacturer specification.
(ii) Horizontal surface: - One coat of integral crystalline water proofing material slurry coat shall be
applied @ of 1.10 kg per sqm or more as specified by the manufacturer specification to harden
concrete. Alternatively integral crystalline water proofing material mix can be dry sprinkled @ of
1.10 kg per sqm and trowel applied to fresh concrete when it has reached initial set.
(iii) Construction joint: - Integral crystalline water proofing material mix shall be applied either as
slurry coat or dry powder consistency immediately prior to placing the next lift/ bay of concrete @
1.60 kg per sqm. or more as specified by the manufacturer specification.
(iv) Binding concrete: - Integral crystalline water proofing material mix shall be applied either as slurry
coat or dry powder consistency immediately prior to placing the overlying concrete slab.
22.16.6 Curing
The treated surfaces should be kept damp for a period of five days and must be protected against direct
sun, wind and frost, by covering with polyethylene sheeting, damp burlap or similar material.

Do not apply Integral Crystalline Slurry at temperatures at or below freezing or to frozen or freezing
surfaces. Integral Crystalline slurry cannot be used as an additive to concrete or plasters. (Integral Crystalline
Admixture should be considered for these applications).

When properly stored in a dry place in unopened and undamaged original packaging its self life
is one year.
22.16.9 Measurement
The Length & breadth/height of the coated area by Integral Crystalline slurry shall be measured in metre
correct to two places of decimal. Measurement shall be made in sqm of the area.
22.16.10 Rate
The rate shall include the cost of all the labour, material and equipments involved in all the operations
described above.
22.17 POLYMER MODIFIED FLEXIBLE CEMENTATIOUS NEGATIVE SIDE WATERPROOFING COATING

WITH ELASTIC WATERPROOFING POLYMERS
22.17.1 Material
Flexible cementatious negative side waterproofing coating with elastic waterproofing polymers is a one-
component, concentrated liquid admixture used to enhance the performance of cementations repair mortars,
plasters, stuccos, concrete mixes and toppings for restoration of horizontal, vertical and overhead concrete;
concrete masonry units (CMU); and masonry surfaces.

1. Flexible cementations negative side waterproofing coating with elastic waterproofing polymer should
have PH value of 7 and consist of liquid state.
2. This should have the density of 1.02 gm per ml.
3. This should posses the property of application in undiluted as well as diluted form.
4. This should be non-reemulsifiable.
22.17.3 Applications
It is to be applied using a long-haired roller, brush or spray on any horizontal, sloping or vertical surfaces
to form a string, flexible, tack-free dry surface. This is easy to use and control in construction works for water
proofing of the surface and optimizes bond to concrete substrates. It also improves resistance to abrasion and
freeze/ thaw cycles.

All substrates must be structurally sound, stable and solid, with all loose material removed. Thoroughly
clean the surface of any substance that could interfere with the bond of the installation material, including dirt,
paint, tar, asphalt, wax, oil, grease, latex compounds, from release agents, laitance, foreign substances pre
existing paint film & loose particles till plaster is visible and any other residues. Concrete surfaces must be
mechanically profiled and prepared by shotblasting, sandblasting, diamond-grinding, water-jetting, scarifying
or other engineer-approved methods to obtain an acceptable profile. Concrete substrate and ambient room
temperatures must be maintained between 45°F and 95°F (7°C and 35°C) before application. Temperatures
must be maintained within this range for at least of 72 hours after the application coating. Application temperature
varies from 70C to 400C.

Apply the coating on to this sound and dry surface using a long-haired roller, brush or spray. The
dilution of the compound the water should be done in a clean mixing pail. The polymer modified flexible
cementatious negative side water proofing coating with elastic water proofing polymers shall be applied on
interior wall plaster surface in three coats @ 14.35 kg/10 sqm or more as recommended by manufacturer
specification. The ratio of mixing with water is to be done in accordance with the nomenclature of the item
along with corresponding coats and manufacturer specifications. One coat i.e. first coat of self priming
cementatious water proofing polymers shall be applied on to the properly prepared and dried surface (diluted
with water in the ratio of 1:1). Another coat shall be applied when the coat below is still wet. Two coats of
cementatious water proofing polymers (diluted with water in the ration of 3:1) over the first coat applied. All
the coats shall be applied in perpendicular direction to each other. The final surface is to be protective from
excessive heat or draft conditions during the first 24 to 72 hours. Final surface should be cured for at least
5 to 7 days. Use of damp burlap, polyethylene sheeting or water-based curing compound is also recommended
to be used for curing.
22.17.6 Measurement
The length and breadth/ height shall be measured in running metre correct to two places of decimal and
the area of applications shall be measured in sqm correct to two places of decimal.
22.17.7 Rate
The rate shall be include the cost of all the labour and material involved in all the operations described
above.
22.18 WATER PROOFING TREATMENT WITH INTEGRAL CRYSTALINE WATER PROOFING DRY-SHAKE
22.18.0 General
Crystalline water proofing dry-shake of hydrophilic in nature is a unique Integral Crystalline chemical
treatment for the waterproofing and protection of concrete. Crystalline water proofing dry-shake has been
formulated for dry-shake applications on horizontal concrete surfaces where greater impact and abrasion
resistance is required.

22.18.1 Material
Integral Crystalline water proofing dry-shake (dry powder) compound consists of Portland cement, various
active proprietary chemicals, and a synthetic aggregate hardener that has been crushed and graded to particle
sizes suitable for concrete floors.
Crystalline water proofing dry-shake becomes an integral part of the concrete surface, thereby eliminating
problems normally associated with coatings (e.g. scaling, dusting, flaking and delaminating). The active
chemicals react with the moisture in the fresh concrete causing a catalytic reaction that generates a non-
soluble crystalline formation within the pores and capillary tracts of the concrete.
Technical Specification/ Parameters:

The Integral Crystalline dry shake material of hydrophilic in nature shall confirm to the following requirements:
cycles. The co-efficient of Permeability calculated as per Darcy’s Formula/Valenta equation by
2. It shall confirm to EN1504-3 (For structural repairs-R3, Compressive Strength > 25 MPa) supplied
from an approved manufacturing unit having CE approval confirming to EN 1504-3R3.
3. The product has no corrosion effect on reinforcement steel according to test norm DINV18998. The
maximum chloride content less than 0.1%.
4. The Integral Crystalline dry shake shall be capable of self-healing of cracks up to a width of 0.5mm.
5. The integral crystalline dry shake, when used in the concrete, will have no detrimental side effects
in terms of Alkali Silica Reaction (ASR), corrosion of Steel Reinforcement etc.
6. The integral crystalline dry shake performance shall not be affected by wear abrasion of the treated
concrete surface and crystalline treated concrete shall not require protection layer.
7. The crystalline water proofing coating/slurry shall be non toxic and suitable for use in potable water
8. The manufacturer shall submit guarantee in respect of crystalline water proofing dry shake
performance for 10 years against any leakage.
Note: The manufacturer shall submit test certificates in respect of all above specification/parameter as stated
above of Integral Crystalline water proofing dry shake material from reputed National/International laboratories
as per relevant codes.
Total quantity of the Integral Crystalline water proofing dry shake material required shall be arranged at
site of work only after obtaining the prior approval of the Engineer-in-Charge in writing. The proper account of
water proofing compound used in the work shall be maintained. It shall be ensured that the consumption of the
compound is as per specified requirements. Contractor shall associate himself with anyone of the applicator
of water proofing compound duly approved by the Engineer-in-Charge before start of work relating to the water
proofing treatment.

22.18.2 Application Rate (Dose)
Crystalline water proofing dry-shake material to be used under normal conditions should cover the application
surface sprinkled @ 0.60 kg per sqm or higher as recommended by the manufacturer specification over the
lean concrete of structure depending upon the degree of abrasion resistance required.
If the surface is to be used under heavy traffic conditions or where greater abrasion resistance is required,
the manufacturers recommendation should be taken into account while applying crystalline water proofing
dry-shake on the concrete surface.

(i) After fresh concrete is placed. Consolidated and levelled, wait until concrete can be walked on
leaving an indentation of 6-8mm.
(ii) Concrete should be free of bleed water and be able to support the weight of a power trowel. Float
open the surface.
(iii) Immediately after floating open the surface and within one hour of finishing the concrete, apply one-
half of the Integral Crystalline water proofing dry-shake material by hand or mechanical spreader, in
one direction only. The Integral Crystalline water proofing dry-shake material must be spread evenly.
(iv) As soon as the Integral Crystalline water proofing dry-shake material has absorbed moisture from
the base slab, it should be power floated to the surface.
(v) Immediately after power floating, apply remaining Integral Crystalline water proofing dry-shake material
at right angles to the first application.
(vi) Allow remaining Integral Crystalline water proofing dry-shake material to absorb moisture from the
base slab and then power float the material into the surface. When concrete has hardened sufficiently,
power trowel surface to the required finish.
22.18.4 Curing
Curing is important and shall begin as soon as final set has occurred but before surface starts to dry.
Conventional moist curing procedures such as water spray, wet burlap or plastic covers may be used. Curing
should continue for at least 48 hours. In hot dry sunny or windy conditions, it is advisable to use an evaporation
retardant on the fresh concrete surface to prevent premature drying of the slab conditions due consultations
should be made from the technical representatives of the manufacturer for specific instructions. In lieu or
moist curing, concrete sealers and curing compounds may be used. In all cases, recommended guidelines
for proper curing should be followed.

Basement Rafts Foundation slab
Water tank base slab Sewage and Water Treatment Plants slab
Below Grade Structures Warehouses Floors
Traffic Bearing Surfaces Parking Structures

For the best results when applying Integral Crystalline dry shake materials, the air content of the concrete
shall not exceed 3% (a high air content can make it difficult to achieve a proper application).
In hot, dry, or windy conditions, it is advisable to use an evaporation retardant on the fresh concrete
surface to prevent premature drying of the slab.

Integral Crystalline dry shake must be stored dry at a minimum temperature of 7º C and its self life is one
year when stored under proper conditions.

22.18.8 Measurement
The quantity of Integral Crystalline dry shake sprinkled area shall be calculated in sqm. The Length &
breadth/height of the Integral Crystalline dry shake sprinkled area shall be measured in metre correct to two
places of decimal.
22.18.9 Rate
The rate shall include the cost of all the labour, material and equipments involved in all the operations
described above.
22.19 CRYSTALINE WATER PROOFING MORTAR

22.19.1 Material
Crystalline water proofing mortar consists of Portland cement, specially treated quartz sand and a
compound of active chemicals.
The active chemicals react with moisture and the by-products of cement hydration to cause a catalytic
reaction, which generates an insoluble integral crystalline complex. These crystalline complexes grow in the
presence of water and block the capillaries of the concrete and minor shrinkage cracks, thus water proofing
the concrete. Chemicals activation begins when the power is mixed with water and may take several days to
completely block the capillaries, depending on ambient temperature and environmental conditions. It can be
applied to the positive or negative water pressure sides of a structure.

1. The crystalline water proofing mortar shall confirm to EN1504-3 having Compressive Strength Class
R4 > 45 MPa and adhesive bond strength Class R3 > 1.5 MPa supplied from an approved
manufacturing unit having CE approval confirming to EN 1504-3R3.
2. It has no corrosion effect on reinforcement steel according to test norm DIN V 18998. The maximum
chloride content less than 0.1%.
3. The crystalline water proofing mortar, when used in the concrete, will have no detrimental side
effects in terms of Alkali Silica Reaction (ASR), corrosion of Steel Reinforcement etc.
4. The crystalline water proofing mortar performance shall not be affected by wear abrasion of the
treated concrete surface and crystalline treated concrete shall not require protection layer.
5. The crystalline water proofing mortar shall be non toxic and suitable for use in potable water
6. The manufacturer shall submit guarantee in respect of crystalline water proofing mortar performance
for 10 years against any leakage.
Note: The manufacturer shall submit test certificates in respect of all above said specification/parameters
of Crystalline mortar from reputed National/International laboratories as per relevant codes.
Total quantity of the water proofing Crystalline Mortar material required shall be arranged at site of work
only after obtaining the prior approval of the Engineer-in-Charge in writing. The proper account of water
proofing compound used in the work shall be maintained. It shall be ensured that the consumption of the
compound is as per specified requirements. Contractor shall associate himself with anyone of the specialist
firms mentioned in approved list of applicator of water proofing compound only approved by Engineer-in-
Charge before start of work.

22.19.3 Recommended Uses
RCC underground structure like basement, water tanks, bridge deck etc.
This material can be applied in conjunction with crystalline water proofing coating for :
(i) Installation of seal strips, reglets and coves at joints to assure water tightness
(ii) Patching and filling / sealing of routed out cracks.
(iii) Patching of tie holes and faulty construction joints.
(iv) Repairing of spalled and honeycombed area.

All surfaces to be patched, repaired or sealed with crystalline water proofing mortar must be clean and
sound. Crack should be routed out to a U-shaped groove, size 25 mm wide and 25 mm deep. Tie holes
should be roughened prior to filling. Spalled and honeycombed area must be thoroughly cleaned and
chiseled back to sound concrete prior to repair. Remove all dirt, cement laitance, form release agents, curing
compounds, paints, coating, etc. by means of wet or dry sand blasting, high pressure water jet or other
approved mechanical means. Surfaces must be well moistened to a dull dampness at the time of application.
The concrete should be damp with no wet sheen on the surface.
22.19.5 Mixing
(i) For routed cracks, coves and non-moving joints: Add water to crystalline water proofing mortar
powder until a medium stiff, trowelable consistency reached. The texture of the mix should be
pliable enough to be trowelled into the cracks with some pressure, but not so pliable that it would
run out or sag out of the crack.
Approximate mixing ratio (by volume) is 4.5 parts crystalline water proofing mortar powder to 1 part
water. Alternatively, 450gm of crystalline water proofing mortar powder to 100 ml of water is to be
mixed or as specified by the manufacturer specification.
(ii) Tie holes and pointing applications: Add only a small amount of water. Mixed consistency
should be that of “dry earth,” holding a shape when squeezed in your hand but easily crumbled
when pressed between fingers. Mix only as much material as can be used within 20 minutes.

(i) For sealing cracks and faulty construction joints, routed out/making U-shape groove size
25x25mm and then priming the surface with integral crystalline slurry @0.05 kg per running meter
and while the surface is tacky filled the groove upto surface crystalline mortar @1.50 kg per running
meter. Once crystalline mortar is touch dry then finally applying two coats of integral crystalline
slurry @0.05 kg per running meter per coat.
(ii) For repairing spalled & honeycombed areas, prepared the surface and chiesel back upto
sound concrete and then primed the area with integral crystalline slurry @0.70 kg per sqm. and
while the surface is tacky repair and level the honeycomb area with crystalline mortar @ 22.70 kg
per sqm. for an average thickness of 10mm. Once crystalline mortar is touch dry then finally two
coats of integral crystalline slurry @ 0.70kg per sqm. per coat.
(iii) For patching of tie rod holes, prepared tie rod hole surface and primed the area with integral
crystalline slurry @ 0.07 kg per sqm and while the surface is tacky repair and filled the tie rod holes
with crystalline mortar @ 0.040 kg per hole. The crystalline mortar shall be tightly rodded into tie
rod holes or packed tightly. For 25x25x25 mm hole, use 0.040 kg per hole to fill the tie rod hole.

22.19.7 Curing
Provide protection against extreme weather conditions, such as heavy rain or freezing conditions, during
the setting period. Curing is not normally required except during hot, low humidity weather. In these conditions,
a light mist of water approximately 25 hours after the repair is completed will help to ensure a controlled cure.
In extreme dry heat, water misting may be carried out at required intervals more frequently.

Crystalline mortar shall not applied at temperatures below 40ºF (4ºC), to a frozen substrate or if temperatures
will drop below freezing during the curing period (approximately 24 hours). This product is not recommended
for use in expansion or construction joints. Crystalline mortar can be applied in (13 mm) layers not exceeding
2.5 inch (approximately 6.5 cm) to prevent shrinkage cracks in the mortar.

Crystalline mortar shall be stored in a dry enclosed area off the ground at a minimum temperature of 7ºC.
Self life when stored in proper conditions in unopened, undamaged packaging is one year.
22.19.10 Measurement
Faulty construction joint will be measured by measuring the length in running meter correct to two places
of decimal.
Repair of honeycombed area will be measured in square meter correct to two places of decimal by
measuring the length and width of treated area correct to two places of decimal.
For repair of tie rod holes, the measurement shall be done for each number of hole.
22.19.11 Rate
The rate includes the cost of all the labour and material involved in all the operations described above.
22.20 SWELLABLE TYPE WATER STOP TAPE

22.20.0 General
Swellable type water stop tape of size 19 mm x 25 mm thick in linear metre (expansive nature) is a unique
sealing compound designed to expand rapidly when exposed to moisture, making it a self-healing joint material
for construction joint applications / treatment .
22.20.1 Material
This is a swellable type sealing compound which expand rapidly after coming in to contact or exposed to
moisture. This acts as a self healing material and is used for applications in construction joints.
22.20.2 Physical Properties

(i) Specific gravity (ASTM D71): 1.35 ± 0.05 (ASTM D-71)
(ii) Volatile matter: 1% maximum (ASTM D-6)
(iii) Penetration, 150g cone at 25°C, 5sec : 40 ± 5mm (ASTM D-217)
(iv) Rate of Rapid Expansion:
(a) Fresh Water Exposure: 24 Hours-140%, 48 Hours- 175%, 72 Hours-190% & 120 Hours-
210%.
(b) Salt Water Exposure: 24 Hours-7%, 48 Hours-12%, 72 Hours-14%, 120 Hours-18%
The water stop material should meet the requirements to EU REACH Regulation (EC) No 1907/2006.

22.20.3 Physical Properties of Swellable Water stop Primer
(i) % Solid : Min 20%
(ii) Flash Point: 93 deg C
(iii) Dry Time : 25 deg C:10 min
(iv) Dry Time : 4 deg C : 60 min
22.20.4 Recommended Uses

Typical applications for swellable type water stop tape include building foundations, raft slabs, retaining
walls, water storage tanks, at the junction of raft slab with the retaining walls and similar non-moving cold
construction joints etc.
22.20.5 Application
(i) The entire surface length where the water stop is to be applied is cleaned thoroughly by using
blower and brush. Apply one coat of required primer throughout the length of the joint @ 3.78 litre
per 240 running metre. Allow the primer to dry for 10 to 15 minutes at the temperature of 25°C. This
should be allowed to dry for some longer time in the areas where the temperature are low.
(ii) By using the heel of the hand and moderate pressure, press the self expanding joint material firmly
into the position on the structure on the entire area which has been primed and dried. Make sure
that the product has bonded with the primed area.
(iii) Where required, splice ends to from a continuous, uninterrupted seal. For best results, cut each
end at opposite 45deg. angles and tightly butt ends together. DO NOR OVERLAP ENDS. Gently
knead the spliced ends creating an uninterrupted seal.
(iv) Peel the protective covering from the exposed side of the installed expandable joints sealing compound.
(v) Pour the matting structural member in position.
Notes:
The manufacturer shall submit guarantee in respect of swellable type water stop tape performance
for 10 years against any leakage.
Always use swellable type water stop primer to avoid displacement of the swellable type water stop
tape during concrete pouring. It may be necessary to utilize masonry nails or other mechanical
means to hold the sealant in place on vertical surfaces.
Place swellable type water stop tape so that it is not closer than 5 cm away from the outer surface
of poured structure. If a Key way is utilized, place the swellable type water stop tape into the
bottom of the formed Keyway area.

Always use swellable type water stop primer to ensure tight adhesion and to aid in preventing swellable
type water stop tape from moving during the concrete pour. For vertical surfaces, nails may be used to hold
the product in place in conjunction with swellable type water stop primer. Swellable type water stop tape shall
be used at a minimum depth of 50 mm inside the concrete. When used on pipes and other structural
penetrations, swellable type water stop tape shall be cut to measured length and placed around the penetration
with ends butted. In all cases, swellable type water stop tape shall be in direct contact with the substrate
along the entire length of the installation. Swellable type water stop tape is not an expansion joint sealant and
only suitable for non-moving concrete joints. Swellable type water stop tape should not be installed in standing
water or on frozen or icy surfaces

When stored in a dry enclosed area off the ground at a minimum temperature of 45°F (7°C) in unopened,
undamaged cartons, its self life is unlimited.
22.20.7 Measurement
The measurement shall be taken by measuring the length of swellable type water stop tape in meter
correct to two paces of decimal.
22.20.6 Rate

APPENDIX A
BITUMEN FELTS (FIBRE HESSIAN BASE)

(Clause 22.8.1.1)
A-1 Weights
The weights of the ingredients used in the manufacture of bitumen felts per 10 sqm shall be not
less than those specified in Table A-I
TABLE A-I
Minimum Weights of Bitumen Felts
S. No. Type of felt For 10 sqm
Untreated Saturant Coatant Bitumen Total weight of the
Base content finished bitumen
felt in dry
condition with
mica dusting
powder Min.
Kg Kg Kg Kg Kg
Fibre Base
(i) Type 2 grade 1 5.0 4.5 12.9 12 22.6
Hessian Base
(ii) Type 3 Grade 1 2.3 1.8 17.7 12.1 23
(iii) Type 3 Grade 2 2.3 1.8 31.8 20.2 37.1
Notes:
1. The weight of the untreated base shall be taken as in the dry condition.
2. Includes allowance for 1.2 kg minimum mica dusting powder in dry condition.
A-2 Testing
A-2.1 Frequency of test shall be decided by the Engineer -in-charge depending on quantum of work.
From each of the rolls one piece 3 m long and the full width of the felt shall be cut out for preparing
test specimens. The first 2M. of the roll shall not be selected for this purpose. The lengths of felt so
selected shall be free from abnormal defects and shall be truly representative of the whole
consignment. The selected pieces of felt shall be dispatched without breakage or distortion, wrapped
up in water proof paper or other similar materials so as to cause no damage to the material during
transit. In case the material has stuck together, no heat shall be applied to separate the layer but the
whole roll shall be sent for testing and the fact shall be reported.
The samples, when tested as per IS1322 shall conform to the requirements given in Table A-II.

TABLE A-II
SI. Type of Breakin Pliability Test Storage sticking Heat Pressure Water
No Felt g tests Resistance head test absorp
strengt Test tion
h kg test
Max.
1 Type 2 (all 95 / 60 (i) The roll The test pieces The test The test 5.0%
grades) shall not show shall be examined pieces shall pieces
cracks on after cooling show no sign shall show
unrolling of melting of no sign of
the bitumen leakage
compound
After release of - -
(ii) Consider the load, the -
any surface layers of felt shall
rupture be capable of
exceeding 5 being separated
mm in length without damaging
as failure the coatant in any
way
2 Type 3 (all 135/90 (i) The roll The test pieces The test The test 2.0%
grades) shall not show shall be examined pieces shall pieces
cracks on after cooling show no sign shall show
unrolling of melting of no sign of
the bitumen leakage
compound
After release of - -
(ii) Consider the load, the layer -
any surface of felt shall be
rupture capable of being
exceeding 5 separated without
mm in length damaging the
as failure coatant in any way

APPENDIX B
GLASS FIBRE BASE BITUMEN FELT

(Clause 22.8.1.1)
B-1 Weight
The weight of the ingredients used in the manufacture of glass fibre felts for 10 square metre
shall be not less than those specified in Table B-I.
TABLE B-I
Minimum Weight of Bitumen Glass Fibre Base Felt
For 10 Square Metre

S. No. Type of Felt Untreated Base Treated Coatant Total weight in dry
Base condition including
surfacing materials
(kg) (kg) (kg) (kg)
1 Type 2 Gr. I -- 0.4 15.3 18.0
B-2 Tests
The sample, when tested as per IS 7193 shall conform to the requirements given in Table B-II
TABLE B-II
Requirements of Glass Fibre Felts
S. No. Properties Requirements
(i) Breaking strength, Min kg (a) Warp 50
(b) Weft 30
(ii) Pliability test (a) Roll shall not show cracks on unrolling
(b) Consider any surface rupture exceeding 5 mm in
length as failure.
(iii) Storage sticking The test pieces shall be examined after cooling. After
release of load, the layers of felt be capable of being
separated without damaging.
(iv) Pressure head The test pieces shall show no sign of leakage.
(v) Heat resistance The test pieces shall show no sign of melting of bitumen
compound.
(vi) Water absorption 2 per cent

Sub Head : Water Proofing Treatment
Clause : 22.1
Fig. 22.1 : Waterproofing of Horizontal Surface of U.G. Structure
Fig. 22.2 : Water Proofing Horizontal Surfaces from Inside of a U.G. Structure

Clause : 22.2
Fig. 22.3 : Waterproofing on Vertical Surfaces of Under Ground Structures

Clause : 22.3
Fig. 22.4 : Position of Horizontal and Vertical Waterproofing Treatment

in Sunken Portion of W.C./Kitchen and the like

Clause : 22.4
Fig. 22.5 : Typical Cross-Section of PVC Water-Stop

Clause : 22.7
Fig. 22.6 : Integral Cement based Waterproofing Treatment with Brick-bat

Coba Over a RCC Slab

Clause : 22.8
Diagrams Not to Scale

Fig. 22.7 : Water Proofing

Clause : 22.9
Fig. 22.8 : Grading Roof Slab with Cement Concrete

Clause : 22.10
Fig. 22.9 : Grading Roof Slab with Cement Mortar 1:3/1:4
Fig. 22.10 : Grading Chajja with Cement Mortar 1:3/1:4

SUB HEAD : 23.0
RAIN WATER HARVESTING &

TUBEWELLS
1207
CONTENTS
23.2 Type of Tubewells 1221
23.3 Drilling Methods 1221
23.4 Accessories to be used in Tubewell Construction 1022
23.5 Information to be furnished by the owner of the 1222

Tubewell
23.6 Information to be furnished by Drilling Agency 1223
23.7 Design and Lowering of Pipe Assembly 1224
23.8 Gravel Packing 1224
23.9 Development of Tube well 1225
23.10 Disinfection 1230
23.11 Grouting and sealing 1231
23.12 Handing over of the Tube well 1231
Appendix-I Annexure-A 1232
Fig. 23.1 Cavity well (for Centrifugal Pump) 1233
Fig. 23.2 Cavity well (for Turbine Submersible Pump) 1233
Fig. 23.3 Tubewell (Natural Gravel Pack) 1233
Fig. 23.4 Tubewell (Artificial Gravel Pack) 1233
Fig. 23.5 Tubewell (Artesial flowing) 1234
Fig. 23.6 Borewell in Hard Rock 1234
Fig. 23.7 Hand Auger 1235
1209 SUB HEAD 23.0 : RAIN WATER HARVESTING & TUBEWELLS

Fig. 23.8 Spiral Auger or Ram's Horn 1235
Fig. 23.9 Simple Jetting Rig 1236
Fig. 23.10 Typical details of Taper reducers, well cap, 1237

V-notch Plate, Centralizing Guide, Bail Plug and
Clamp
Fig. 23.11 Closed Well Development With Air Compressor 1238
Fig. 23.12 Open Well Development With Air Compressor 1239
Fig. 23.13 Surge Block 1240


1. IS 226:1975 Structural Steel
2. IS 460:1985 (Part-1) Code of practice for particle size distribution
3. 1239 (Part I):1990 Mild steel tubes, tubulars and other wrought steel fittings:
Part I Mild steel tubes (fifth revision)
4. 2800 (Part I): 1991 Code of Practice for Construction and Testing of Tubewells/
Borewells
5. 3589 :1991 Seamless or electrically welded steel pipes for water, gas
and sewage (1683 to 2032 mm outside diameter) (second
revision)
6. 4097: 1967 Gravel for use as pack in tubewells
7. 4270 : 2001 Steel tubes used for water wells(second revisions)
8. 8110 : 1985 Well Screens and Slotted Pipes
9. 9439 : 1980 Glossary of terms used in water-well drilling technology
10. 10500 : 1983 Drinking water
11. 10151 : 1982 Polyvinyl chloride (PVC) and its copolymers for its safe use
in contact with foodstuffs, pharmaceuticals and drinking water
12. 11189 : 1985 Methods for tubewell development
13. 12818 : 2010 Unplasticized PVC ribbed screen casing and plain casing
pipes for bore/ tubewells - Specification

23.0 RAIN WATER HARVESTING & TUBE WELLS
23.0 TERMINOLOGY
Acidizing: The process of introducing acid into the pore spaces of acid soluble formations to enlarge
the pore space by dissolving the surrounding formation. Acidizing also refers to the removal of
encrustation from well screens and gravel pack, and dissolving cementations materials.
Additive: An auxiliary agent added for conditioning of drilling fluid to obtain desired physical properties.
Air Drilling: The drilling process in which air or gas is used as a medium for removal of cuttings.
Air Line: The small diameter vertical pipe inserted in the tube wells with or without the ejector for
cleaning and developing tube wells by airlift method.
Air Line Lubricator (In-Line Oiler): An apparatus that feeds a small controllable quantity of lubricating
oil into the air stream to provide lubrication for pneumatic components/accessories of machines.
Air Rotary Drilling: A process similar to direct circulation rotary drilling except that compressed air is
used as a drilling fluid instead of drilling mud.
Annular Space: The space between drill pipe and wall of the hole, or Casing and wall of the hole, or
Drill pipe and casing.
Annular Velocity: The up-hole return velocity of fluid or air in the annulus, usually expressed in m/
min.
Antlfoam: An agent added to acid to prevent or retard foaming during the acid reaction.
API (American Petroleum Institute): The designation given to equipment or parts of equipment
standardized by the American Petroleum Institute, such as drill pipe threads.
Aquifer: An aquifer is a geological formation, group of formations, or part of a formation that contains
sufficient saturated permeable material to yield significant quantities of water to wells and springs.
Artesian: Artesian is synonymous with confined artesian water and artesian water bodies are’
equivalent respectively to confined ground water and confined water body. An artesian well is a well
deriving its water from an artesian or confined water body. The water level in an artesian well stands
above the top of the artesian water body it taps.
Artesian Well: A Well tapping confined or artesian aquifer in which the static water level stands
above the water table, in which case those wells with water level above the water table are said to
have positive artesian head (pressure) and those with water level below the water table, negative
artesian head.
Bailer: A tube fitted with a valve at its base, which is lowered into a bore hole to remove cuttings and
water.
Barrel: Unit of measurement consisting of 42 US gallons.
Barite: Barium sulphate, the commercial product contains small amounts of iron oxide, silica, and
other minerals. It is used to make mud heavier.

Barytes: Natural barium sulphates, used as a basic material for weighing agents.
Bentonite: A finely powdered, highly plastic, colloidal material used in preparing drilling mud.
Bit: The cutting element attached to the bottom of the drill stem. Can be of various types - for
example, Rock roller, Drag, Diamond, Tungsten carbide tipped, etc.
Bit Breaker: A heavy plate, which fits in the rotary table and holds the bit while it is being unscrewed
from the drill stem.
Bit Nozzle: A fluid port in the bit.
Blocks, Crown and Travelling: An assembly of a pulley(s) mounted to rotate on an axis, with a
hook or eye for anchoring or attaching to load. Pulley(s) are grooved for the wire rope. It is used to
raise or lower the drill string.
Blowout: A sudden escape of violent escape of gas, oil or water from a drilling well when high
pressures are encountered and efforts to prevent or control the escape are unsuccessful.
Bore Hole: Any hole bored/drilled in the ground for prospecting of oil, minerals or ground water.
Blowout Preventor: A device attached immediately above the casing to control pressures and
prevent escape of fluids from the annular space between the drill pipe and casing or to shut off the
hole if no drill pipe is in the hole, should a kick or blowout occur.
Breakout: The act or process of unscrewing a threaded joint - especially in case of drill pipes while
it is being withdrawn from the well bore.
Bridge: An obstruction to circulation between the annular space of the well. A bridge is usually
formed by caving of the wall of the well bore or by the intrusion of a large boulder
Cable Tool Percussion Drilling: A spudding process in which drilling is carried out by lifting and
dropping a heavy string of drilling tools at regular intervals, resulting in crushing or loosening rock
formations. The reciprocating action of the tools mixes the crushed or loosened particles with water
to form a slurry or sludge. Necessary water is put into the borehole if no water is present in the
formation being penetrated. The slurry is removed at intervals from the borehole by means of a sand
pump or a bailer.
Casing Pipe: Piping used to support the sides of borehole.
Casing Shoe: A heavy-walled steel coupling or band at the lower extremity of the casing. It clears
the way for casing.
Cathead: An auxiliary hoisting device used for handling light loads and for alternately lifting and
dropping tools such as drive block or bumper. Its use requires a line of manila/wire rope carried on a
separate sheave at the top of the derrick. It is also used for making and breaking the joints.
Catline: A hoisting or pulling line used in conjunction with the cathead to lift heavy equipment or
tools.
Catwalk: A ramp on the side of the drilling rig, fitted to the derrick floor, where the pipes are laid using
the catline.

Cementing: The process of placing the cement slurry to provide a seal against subsurface water.
Cement Plug: The hardened cement slurry left in the lower portion of the casing and later drilled out
after the cement has set.
Cement Slurry: A pumpable mixture of cement and water.
Circulate (Normal): To pump drilling fluid from the pit, through the drill pipe and back to the surface
through the annulus. The term generally applies to the operation carried out when drilling is temporarily
suspended, to obtain samples from the bottom or to keep the hole in condition while awaiting other
operations.
Circulation, Direct (Drilling): The drilling fluid movement from the mud pit to the annular space in
the hole, drill pipe, kelly water swivel, suction hose, centrifugal or jet pump, settling pit and back to
mud pit.
Co-efficient of permeability: is the velocity of flow through a permeable material at hydraulic

gradient unity.
Collapse Strength: It is the strength of screen to withstand surrounding hydrostatic pressure on

outside surface.
Control Console: A horizontal or vertical panel on which the entire operator’s controls are located.
Coring: The act of procuring a sample of the formation being drilled for geological investigation.
Coring is done using a core barrel.
Crown Block: An assembly of wire line sheaves mounted on the uppermost portion of the derrick/
mast.
Cuttings: Particles of formations obtained from the well during drilling operations. These can be
brought to the surface by the circulating fluid or air in rotary drilling or bailed out in case of cable tool
drilling.
Deadline: Refers to the end of the drilling line, which is not related on the run. This end is usually
anchored to the mast substructure and does not move as the block moves up or down during various
operations.
Die Overshot: A long tapered die of heat-treated steel designed to fit over the top of the lost drill
pipe and cuts thread when rotated. The tool is fluted to permit the escape of metal cuttings and
fluids.
Dilution: The use of more water in the cement slurry than is necessary to produce pumpable slurry.
Direct Circulation Rotary Drilling: This process consists of drilling a borehole by means of a
rotating bit and removing the cuttings by continuous circulation of drilling fluid as the bit penetrates
the formation materials. The drilling fluid flows from the mud pit, through the pump, stand pipe, hose,
drill pipe, annular space in the hole, and settling pit, back to the mud pit.
Directional Drilling: An operation in which a hole is purposely deviated in a controlled direction and
angle.
Down-the-Hole Drilling: A method of drilling using down-the-hole hammers.

Down-the-Hole Hammer: A percussive air operated tool attached to the end of the drill string used
in down-the-hole drilling. Tungsten carbide tipped bits are normally used with down-the-hole hammers.
Drag Bit: A rotary bit, which has two or more cutting blades, or wings with hard faced cutting edges.
Drawdown: Lowering of water level caused by pumping. It is a measure for a given quantity of water
pumped during a specified period, or after the pumping level has stabilized.
Draw-Works: A power-driven winch or winches, usually equipped with clutch and brake for hoisting
or lowering a drilling string.
Drill Bit: Drilling tool deployed in drilling operations and attached at the end of the drill string.
Drill Collar: A heavy drill pipe used immediately above the drill bits to put weight on the drill bit and
minimize deviation of the hole.
Driller: A person who operates the drilling machines or rigs.
Drill Pipe: Special pipe, with threaded tool joints at both ends, used to transmit rotation from the
rotating mechanism, thrust and weight to the bit and convey fluid, which removes cuttings from the
hole and cools the bit.
Drill String: Components including subs, adaptors, drill pipe, drill collar, bit etc, joined together to
form a drill string depending upon the type of rig used for drilling the hole.
Drive Bushing: Device used to transmit torque from the rotary table /drill head to the kelly but allow
vertical movement of the Kelly while drilling.
Drive Head: A sub fastened to the top of pipe or casing to take the blow of drive weight.
Drive Pipe: A pipe or casing driven through over-burden.
Drive Weight: Normally used in percussion drilling to give blows on top of casing to drive it. Also
called drive hammer or drive block.
Dry Hole or Duster: A well drilled. which produces neither oil nor gas nor water of significant quantity.
Dust Collector: Used to control the dust and/or collect the cuttings which are discharged from the
hole being drilled by air drilling.
Dust Diverter: Collar and hose used to divert dust and cuttings away from the operator and the
machinery.
Elevators: Devices which latch around the drill pipe/casings attached by links to the travelling block
that raises or lowers the pipe/casing from the hole.
End Rings: These are rings or couplers welded at both ends of screen to facilitate joining with other
pipes.
Expansion Reamer: A device or tool haying cutters that can be expanded or contracted by hydraulic
or mechanical means and used to enlarge or ream bore hole below the casing or drive pipe. Also
known as adjustable or under reamer.
Feed: The process of applying required pressure on the cutting tool to achieve the downward
movement.

Fish: Debris in the hole such as broken bits, drill pipe, casing tools, etc, which may have broken off
and lodged in the hole.
Fishing: The act of attempting to recover a fish.
Fishing Magnet: A special powerful magnet attached to a rope or drill string to fish out magnetic
material.
Fishing Tap: A tap of heat-treated steel designed to fit to the top of the lost drill pipe and cuts thread
when rotated. The tap is fluted to permit the escape of the metal cuttings and fluids.
Fishing Tools: Special tools used to retrieve fish from the hole.
Fluid, Drilling: The medium, liquid or gas used for flushing cuttings from the hole being drilled for
cooling the bit and for lubricating the bit.
Foam Flushing: A liquid chemical added to the flushing water to stabilize the hole walls and to
remove the drill cuttings effectively.
Gel Strength: A measure of the effect of the forces between the particles while the mud is at rest.
Hoisting Line: Wire rope used on the draw-works to hoist and lower the drill string.
Hole: Usually refers to the well bore.
Hook Load: The load, which may be applied to the hook, attached to the travelling block on a drill rig.
Hydraulics: That branch of engineering that deals with liquids in motion. It is the know-how about
the effects of fluid velocities and pressures and the power involved.
Hydraulic Percussion Drilling: This is also known as hollow-rod drilling method. It employs a chisel
shaped bit. A ball check valve is provided between the bit and lower end of the drill pipe string.
Drilling is done by lifting and dropping the drill rods/ bit with quick short strokes. The drilling fluid is
supplied at the surface in the annular space. It enters the ball check valve during downward stroke of
drill pipe. When the bit is picked up, the ball check valve closes and traps the fluid inside the drill
pipe. Continuous reciprocating motion produces a pumping action to lift the fluid to the top of the
string of drill pipe where it discharges into a settling tank.
Idler: In machinery an idler pulley or sprocket is used in connection with belt drive and chain drive
respectively to maintain desired tension in the belt or chain.
Impression Block: This block has many forms and designs and often used to obtain an impression
of the top of the fish before attempting fishing operations.
Jet: A directed, rapid flow of fluid from a nozzle.
Jet Percussion Drilling: In this method, a chisel-shaped bit is attached to the lower end of string of
pipe. Holes on each side of the blades of the bit serve as nozzles that help in loosening the material
being drilled and keep the bit clean. The drill rods are rotated by hand to make the drill cut a round
hole. The drilling fluid flows from the mud pit through the pump, stand pipe, hose, drill pipe and
comes out through nozzles in the bit. It then flows through the annular space to settling pit and back
to mud pit. With fluid circulation maintained, the drill rods are lifted and dropped in a manner similar
to cable tool drilling but with shorter strokes. The bore hole is thus drilled by chopping action of the
bit combined with washing action of water jets.

Kelly: A formed or machined section of hollow drill steel which is joined directly to the swivel at the top
and to the drill pipe below. The flats or flutes of the Kelly engage the rotary table so that the rotation
of the rotary table is transmitted to the kelly, which, in turn, transmits it to the drill pipe and consequently
to the rotary bit.
Laminar Flow: Movement of fluid particles in essentially parallel paths.
Loss of Circulation: The loss of drilling fluid into formation pores or crevices.
Making a Joint/Connection: The act of screwing a joint of the drill pipe on to the drill stem suspended
above the well bore.
Making Hole: Drilling ahead.
Mast: A structure on the rig used to support the crown block, top drive, pull down chains, hoisting
lines, etc. It is also called Derrick or Tower.
Marsh Funnel: A calibrated funnel commonly used in field tests to determine the viscosity of drilling
mud.
Master Bushing: Adaptor used to reduce the size of the rotary table opening to accommodate
various sizes of bushings, slips, etc.
Mud Balance: An instrument consisting of a cup and a graduated arm with a sliding weight and
resting on a fulcrum used to measure weight of the mud.
Mud Gun: A pipe that shoots a jet of drilling mud under high pressure into the mud pit to mix the
additives and to stir the mud for other reasons.
Mud Mixing: Preparation of drilling fluid from a mixture of water or other fluids and one or more of
various dry mud making materials such as clay, weighing materials. chemicals, etc.
Mud (Slush) Pump: A large single acting triplex or double acting duplex pump used to circulate mud
down the drill pipe and up the annulus, under normal operations.
Nozzle: A small spout to direct the flow of fluid efficiently.
Penetration, Rate of: The rate at which the bit proceeds in the deepening of the well bore.
Penetration: It is the amount of penetration between profile wire and support rod after fusion welding.
Percentage Open Area: It is the open area available for entry of water as percentage of total
outside surface area of pipe.
Permeability: Permeability or hydraulic conductivity of a medium is indicative of the ease withwhich

water can flow through it. It depends on the properties of the medium affecting flow includingporosity,
packing, shape, and grain size distribution.
Pipe Handling Equipment: The equipment for storing, adding and removing lengths of drill pipe.
Power- Take-Off: The means of transmitting power from the engine of the power package, or a
truck or tractor, to the othercomponents of a drilling rig. This is usually accomplished by a separate
shifting arrangement in the transmission.
Profile Wire: Shaped wire which is spirally wound.

Pull Down: Thrust or weight applied to the bit through the drill string, and the mechanism, which
provides either, the hoisting or pulling power.
Push Strength: It is the maximum separating force that weld joint between profile wire and support
rod can withstand.
Ratio of Submergence: This is the ratio between the length of the airline under water to the total
length of airline.
Reamer: Cutting tool used to enlarge a bore hole.
Reaming: The operation of smoothening the well bore, enlarging the hole to the desired size.
Reverse Circulation Rotary Drilling: In this drilling process, a string of drill pipes with a drill bit at
the bottom is rotated by mechanical means. Plain water or a fluid of gelling quality is circulated to
prevent the hole from caving in and for sucking up the drill cuttings through drill pipes. The flow of
drilling fluid takes place from the mud pit to the annular space then through the opening in the bit to
the drill pipe, a centrifugal pump or jet ejector, settling pit and back to mud pit.
Rig: A drilling machine used for drilling a borehole.
Rotary Drive: Use of a power shaft to transmit driving power to the rotating element.
Rotary Hose: The air or mud hose that leads from the stand pipe to the swivel. also known as the
‘fluid (air) or swivel hose.
Rotary Table, Power Swivel, and/or the Rotation Drive: The means of transmitting rotation to
the drill string and bit.
Safety Hook: A hoisting hook with a spring-loaded latch that prevents the load from accidentally
slipping off the hook.
Sand Content: The percentage bulk volume of sand in a drilling fluid,
Shale Shaker: A vibrating screen that removes coarser cuttings from the circulating fluid before it
flows into the return pit.
Sheaves: Disc type or wheel type parts of the travelling blocks or crown block with the circumference
grooved for a selected diameter of drilling lines, These can be mounted on bushings’ or bearings.
Slips: Wedge or wedges used to prevent the drill pipe or casing pipe from slipping through the
opening in the rotary table when the bit is off the bottom during trip or when adding or taking off a
section of drill pipe. These may be hand or power-actuated.
Slotted Pipes: Slotted pipes are pipes with slots cut into them in a pattern suitable to the basic
material of the pipe.
Slot Opening: It is the width of opening for entry of water.
Slurry: A mixture of cement and water that is pumped into the well to cement casing.
Slush (Mud) Pit: Pit used for mixing the drilling fluids and to act as a storage/settling tank for the
return cuttings.

Specific Capacity: The ratio of the discharge to the drawdown it produces measured under the well (l/min/m
of drawdown).
Stabilizer: Fixed to the drill string to provide stability to the drill string - can be spaced out over the entire
length of the string.
Stand Pipe: A vertical pipe or hose carrying either air or mud to approximately the middle of the mast where
it is connected to the mud, rotary or swivel hose.
Sub: A substitute, or adaptor, which is used to connect from one type or size of threaded connection to another.
Support Rods: The longitudinal shaped/circular rods supporting the profile wire.
Swivel: The mechanism, which permits the passage of mud or air from a stationary hose into a rotating
member, such as the kelly or drill pipe.
Tensile Strength: It is the strength of the screen to withstand tensile load.
Thinner: A substance that reduces the apparent viscosity and get development of mud without lowering the
density. The addition of thinner affects the colloidal clay fraction of mud.
Thread Protector: A coupling type device which is screwed onto or into both ends of a pipe to protect the
threads from damage during transportation, storage or moving around the drill site.
Tongs: The tools used in making or breaking a joint of pipe during a drilling operation. Their action is much the
same as that of a pipe wrench.
Tool Joint: Threaded portions of the drill string, which may be either box or pin type.
Tower: See Mast.
Transfer Case: A transmission to distribute power from the engine to other rig components.
Tube well efficiency: The formation loss (head loss) required to produce flow divided by the total drawdown
observed in the well.
Wall Hook: A simple tool that can be made from steel casing, shaped with a cutting torch. A reducing sub
connects the top end of the tool to the drill stem. Also used to straighten the lost drill pipe in the hole in
preparation for removal by the tap or overshot tools.
Water Injection System: Used for adding water to the down-hole air stream, thereby increasing the efficiency
of the cleaning action. Also used for controlling dust in the hole.
Water Table: That underground level at which water is found.
Water-Well: Term used for any type of ground water structure providing space for accommodating water
lifting device for drawl of ground water.
Well Development: Development of aquifers by compressed air or any other suitable method.
Wetting Agent: An additive that reduces surface tension.
Well Development: It is a treatment of a well to establish the maximum rate of usable water yield without sand.
Well Screens: Well screens are specially fabricated screen pipes from different materials which can have
wider range of slot opening from much finer to coarse compared to slotted pipes.

23.1.1 Rainwater harvesting is the collection of rainfall. In most cases, a roof is used for this purpose.
The rainwater then flows through the gutters, into a collection tank. The collected water can be used
for small scale irrigation (of vegetable gardens etc.), clothes washing, bathing and after treatment
also for drinking and food preparation.
23.1.2 Rainwater offers advantages in water quality for both irrigation and domestic use. Rainwater
is naturally soft (unlike well water), contains almost no dissolved minerals or salts, is free of chemical
treatment, and is a relatively reliable source of water for households
23.1.3 A rooftop rainwater harvesting system consists the following elements:

(a) Collection area
(b) Conveyance/piping system,
(c) Filtration /treatment
(d) Storage
(e) Usage/ Recharge
23.1.4 The collection area in most cases is the roof of a house or a building. The effective roof area
and the material used in constructing the roof influence the efficiency of collection and the water
quality.
23.1.5 A conveyance system usually consists of gutters or pipes that deliver rainwater falling on the
rooftop to manholes or other storage vessels. Both drainpipes and roof surfaces should be constructed
of chemically inert materials such as wood, plastic, aluminum, or fiberglass, clay tiles etc in order to
avoid adverse effects on water quality.
23.1.6 The water ultimately is stored in a storage tank, which should also be constructed of an inert
material. Reinforced concrete, Brick masonry, fiberglass, or stainless steel are suitable materials.
Storage tanks may be constructed as part of the building, or may be built as a separate unit located
some distance away from the building.
23.1.7 Design of various component of systems for Rain Water Harvesting are covered in the CPWD
Rain Water Harvesting and conservation Manual.
23.1.8The specifications of various types of piping systems used in RWH, manholes, manhole covers,
Open surface drains, road gully chamber, Dispersion trenches, soak pits are provided in the CPWD
specifications Sub Head: Drainage.
23.1.9The Specifications for Storage tanks/Underground sumps shall be followed as per IS 2470:
1986 (Part I & II).
23.1.10 The recharge wells/pits are provided with the bore wells to recharge the ground water table
directly draining rainwater through filter media to the aquifer.
23.1.11. The recharge wells/pits are also used for drawing water from the aquifer by making deep tub
well in the or near the recharge pit.
23.1.12 The specifications for tube well for the withdrawal of underground water are also provided in
this chapter.

23.2 TYPE OF TUBEWELLS:
23.2.1 Type 1 (Cavity Well)
Cavity wells are generally shallow wells drilled in alluvial formations (see Fig. 23.1 and Fig. 23.2).
These are wells with casings resting in thick, hard impervious clay layer above the aquifer. It is a pre-
requisite that the impervious clay layer should be of adequate thickness to support the well and
should not disintegrate when water is pumped out.
23.2.2 Type 2 (Tubewell)

Tubewells are generally constructed in alluvial formations comprising a casing pipe, .ahousing
pipe (if need be) and an intake section either screen or slotted pipe with or without gravel packing
(artificially packed or naturally packed wells as shown in Fig. 23.3 and Fig. 23.4). These wells may be
either under water table conditions or under artesian conditions (see Fig. 23.5).
23.2.3 Type 3 ( Borewell in Hard Rock Formation)

The over-burden in such wells is encased to eliminate the risk of caving in. Drilling is further
carried out in rock formation and the bore is left normally unsupported to allow the water to flow from
crevices and fishers into the bore except in -cases where caving formations are encountered (see
Fig. 23.6).
23.3 DRILLING METHODS: The various terms of water well drilling are to be read as per
IS 9439 : 2002. The various methods of drilling as per IS 2800 (Part-I) : 1991 are as
below:-
23.3.1 Auger Drilling

The drilling is done with a spiral or worm auger connected to square rods turned manually with
rod tillers, the cuttings produced as a result of drilling are removed with a sand shell. Steel casing
pipes with drive shoes at the bottom are lowered as the drilling progresses. This method is employed
where very shallow drilling in alluvium formation is involved (see Fig. 23.7 and Fig. 23.8).
23.3.2 Water Jet Boring

A drill bit with nozzles is attached to the drill pipes at its bottom and through which water is
pumped at high pressure. The water on its return flow through the annular space between the bore
and the drill pipe, brings out the cutting along with it to the surface. ‘Casing pipe is simultaneously
used to avoid caving in. The method is suitable for drilling shallow wells in loose sandy formations
(see 23.9).
23.3.3 Calyx Drilling

A bit made from hollow steel tube with two inclined slots called ‘shot bit’ is connected below
another tube (core barrel) which is further connected to the drill rods. These are rotated mechanically.
Chilled shots are fed to the bottom of the bit through the drill string along with water. These are
ground by the shot bit to form abrasive material with sharp edges which cuts into the consolidated
formation forming an annular ring to form a core inside the core barrel, which is then taken out from
well by grouting the core with quartz chips, etc.: This method is successful for shallow tubewells
drilling in consolidated formations with large diameter holes.
23.3.4 Percussion Drill Hog

A heavy bit attached with a drill stem, a drilling jar to a cable is given up and down spudding
motion, either manually or by power. Water is added to dissolve the cuttings which ate lifted out by
means of a bailor. Steel casing pipes with drive shoes are used as the hole progresses. This method
of drilling is suitable for drilling in boulder formations.

23.3.5 Rotary Drilling
23.3.5.1 Direct Circulation Method
A drill bit is rotated mechanically by means of drill pipes, through which drilling mud (usually bentonite
mixed with other suitable material) is circulated under pressure. This process of circulation lubricates
the bit, carries the cutting in suspension to the surface and also plasters the wall of the hole to prevent
it from caving-in. Very deep wells cm be constructed in alluvium formations by this method.
The accessories commonly used for tubewell construction, their description/ functions and the
typical material for their manufacture are given in Table 1.
23.3.5.2 Reverse Circulation Method

A starting of drill pipes with a drill bit at the bottom is rotated by mechanical means. Plain water or
a fluid of gelling quality depending on the strata conditions, is allowed to Row into the bore hole,
when drill cuttings along with water are sucked through the drill pipes by a centrifugal pump and
thrown into the setting pit. The hole remains intact under the -hydrostatic pressure of the drilling
fluid, the level of which is maintained continuously. Large diameter holes can be drilled in alluvium
formations by this method.
23.3.6 Down the Hole Hammer (DTH) Drilling

The method is used for fast and economical drilling in ·bard formations. Compressed air is utilized
for rapid impacting action by the hammer to the bit thus crushing the formation into small chips which
arc flushed out through the annular space between the bore and the drill pipes by the upcoming
compressed air.
Note:- The drilling bits generally used during the drilling by direct circulation method and by
reverse circulation method are tricone rock roller bits, diamond drilling bits, reaming bits and thin wall
core bits. Their use depends upon the type of soil format-ions such as soft, medium hard and hard
formations. The bits used for percussion drilling are California pattern bits and for DTH drilling are
button bits and drag bits.
23.4 ACCESSORIES TO BE USED IN TUBEWELL CONSTRUCTION

23.4.1 A typical drawing showing details of bail plug, bail plug hook, centralizer, taper reducer, mild
steel clamp, well cap and notch plate, is given in Fig. 23.10.
23.4.2 The description, functions and the material of accessories commonly used for tubewell
construction is given in Table-1.
23.5 INFORMATION TO BE FURNISHED BY THE OWNER OF THE TUBEWELL:

The owner shall furnish the following information to the drilling agency:
(a) Information regarding tubewells and dug well existing near his land such as their depth,
formation encountered and discharge, etc. may be furnished as far as possible;
(b) Static water level;
(c) Expected yield;
(d) Purpose for which the water is needed, such as irrigation, industrial or domestic purpose,
etc; and
(e) Any other information.

23.6 INFORMATION TO BE FURNISHED BY DRILLING AGENCY:
When offering to sink a tubewell, the drilling agency shall furnish the owner with the following information:
(a) Suitably of the site proposed by the owner -( if a more suitable site, other than the one proposed by
the owner is available, it should be suggested );
(b) Whether a test bore hole .is proposed and if so, its diameter and depth, and also depth of production
tubewell proposed;
(c) Likelihood of increase or decrease of the depth given at (b) above;
(d) Method of drilling with size of bore in different depths;
(e) Types of plain pipe with size, wall thickness and slotted/strainer pipes with opening, may be
mentioned:
(f) Guarantee with regard to the verticality of tubewell and sand content ( ppm) in the discharge from
the well at the time of handing over;
(g) Development methods to be adopted may be stated; and
(h) Any other information and conditions.
TABLE 1
Nomenclature of Tubewell Parts
(Clause 23.4 and Fig. 1, 2 and 3)
Sl. Name of Part Description/ Function of Part Typical
No. Materials
(1) (2) (3) (4)
1) IS 226 : 1975
Bail plug or bottom plug A closed socket provided at the bottom most end of the pipe
assembly. A simple mild steel plate welded at the bottom
end.
2) IS 226 : 1975
Bail plug hook Inverted 'U' hook attached to the bottom plug or a bar fitted
across the blind pipe.
3) Casing pipe IS 4270 : 2001
Placed against strata from which water is not to be tapped.
or
IS 12818 : 2010
4) Screens/ slotted pipes IS 8110 : 1985
Has openings to permit entrance of water from the
aquifer.
5) Centralizer IS 226 : 1975
The centralizing guides are fitted to the well assembly except
-the housing pipe at suitable spacing to keep the assembly in
the centre of the hole So that an even thickness of ravel
pack.
6) Taper/ reducer IS 226: 1975
A taper/reducer is intended to connect the housing pipe with
lower diameter assembly down below.
7) Housing pipe IS 226 : 1975
This is the upper portion of 'the case section of the well and
serves as a housing for the pumping equipment and is a
vertical conduit through which water flows from 'the aquifer to
the pump. It is water tight and extends from to a depth below
the anticipated pumping water level.
8) Clamp IS 226 : 1975
Fixed at the top of the tubewell for supporting the well
assembly.
9) Well cap IS 226: 1975
Used to keep the tubewell closed after its completion until the
pump set is installed. It is either threaded to be screwed to
top of the housing or simply a plate is spot welded so as to
be easily removed when required.

23.7 DESIGN AND LOWERING OF PIPE ASSEMBLY
23.7.1 Design of Pipe Sizes and Lengths
The length and diameter of the casing pipe is selected on basis of static water level, the draw down, the
discharge expected from the well and the size of pump to be installed. The size and length of slotted/strainer
pipes are selected according to the actual requirement according to the strata met with the expected discharge
end the depth of tubewell, the casing pipes shall generally conform to IS 4270 : 1983, the slotted/strainer pipes
shall conform to -IS 8110 : 1985 and the u-PVC casing pipes and screen shall conform to IS 12818 : 2010.
23.7.2 Design of Screen Slots

The entry of water in the tube well shall be either through screens or slotted pipes. Following are the
various types of well screens and slotted pipes used in water wells depending upon the type and size of well:
(a) Plain slotted pipe,
(b) Bridge slotted pipes,
(c) Mesh -wrapped screens,
(d) Cage type wire wound screens,
(e) Pre-packed resin bonded gravel screens,
(f) Brass screens.
(g) u-PVC pipes
The design, selection and type of screen or slotted pipe size and distribution of slots shall be as specified
in IS 8110 : 1985.
23.8 GRAVEL PACKING

23.8.1 All gravel to be used as pack in tubewell construction for water supply shall be as specified in IS 4097:
1967. The thickness of the gravel shroud around the screen shall generally be not less than 10 cm.
23.8.2 The gravel selected for packing tubewells shall consist of hard quartz (about 96 percent SiO2) or
other suitable material, with an average specific gravity of not less than 2.5. Not more than 10 percent by
weight of the material shall have a specific gravity of less than 2.25. The gravel shall contain not more than two
percent by weight of thin flat or elongated pieces. In the case of such pieces, the larger dimensions shall not
be more than 3 times the smallest dimensions. The quartz shall be of sub-rounded to rounded grains with
minimum angular features.
23.8.3 The gravel for use as pack shall be free from impurities, such as shale, mica, feldspar, clay, sand, dirt,
loam, and hematite and organic materials.
23.8.4 The porosity of the gravel when laid as a pack shall not be less than 25 percent.
23.8.5 Gravel Sizes: The gravel conforming to this standard as per IS 4097 : 1967 shall be of the following grades:
Sl. No. Grade Pack Particle Size IS Sieves

Range (see IS:460-1962*)
Mm
1 A Fine Gravel Over 2.0 to 3.35 2.0 , 3.35
2 B Fine Gravel Over 3.35 to 4.75 3.35 , 4.75
3 C Medium Gravel Over 4.75 to 6.3 4.75 , 6.3
4 D Medium Gravel Over 6.3 to 8.0 6.3 , 8.0
5 E Coarse Gravel Over 8.0 to 12.5 8.0 , 12.5

Note:- The particle size distribution of gravel shall be determined by screening through standard
sieves in accordance with IS: 460-1985. The percentage distribution of the sizes shall be determined
from a graph in which the percentage of material passing through each sieve is plotted against the
standard aperture of that sieve. Any size, say D20, will thus indicate that the cumulative weight of all
the grains smaller than this size is 20 percent of the total weight of the test sample. The uniformity
coefficient of the gravel, that is, the ratio of its D20to D10sizes shall not exceed 2. A material
with uniformity coefficient less than 2 shall be classified as uniform and if greater than 2 it shall be
taken as non-uniform. The limiting sizes given in above table are the minima and maxima, and the
stacks containing smaller or bigger sizes as shown by sieve analysis shall be rejected.
23.8.6 The gravel shall have a hardness of not less than 5 in Moh’s scale.
23.8.7 The pack aquifer ratio ( P/A ratio) is defined as the ratio of 50 percent size ( D30) of the
gravel pack to the 50 percent size of the aquifer. The size of gravel when used as pack in tubewells
shall be decided in accordance with the size of the aquifer material proposed to be tapped. The
gravel size shall be limited as below:
(a) Uniform aquifer with uniform gravel pack.
Pack aquifer ratio — 9 to 12.5
(b) Non-uniform aquifer with uniform gravel pack.
Pack aquifer ratio — 11 to 15.5
Note:-The thickness of gravel pack shall be limited to 13 to 18 cm.
Note:- However, artificial gravel pack may not be necessary if the effective size (D10) of the aquifer
is greater than 0.3 mm and its uniformity coefficient is greater than 5. For artificial gravel pack, pl see
Fig. 23.4.
23.8.8 For sampling and packing, corresponding provisions of IS 4097 : 1967 may be referred.
Note1: In percussion method of drilling, .gravel is fed into the annular space between the casing
pipe and the assembly pipe up to 3 m above the bottom of the slotted pipe. The well is developed
using compressed air or by bailers and as the water becomes clear, surging or backwashing is done
to make the development more perfect. More gravel is fed, if necessary, and when the water becomes
free from sand, the casing pipe is jacked up to some height, and the process is repeated until all the
aquifers are gravel packed.
Note2: In rotary method, the pipe -assembly is lowered into position and gravel packing may be
done up to a suitable depth below the bottom of the housing pipe in the first instance. There after the
gravel packing up to the required depth is completed after keeping the housing pipe vertical within
limits. To achieve uniform gravel packing around the pipe assembly inverted cones should be used.
Note3: A provision for a well base to eliminate the possibilities of subsidence of the well structure
may be incorporated. If the bottom of the well is in a soft formation, the well should be provided with
an artificial base for the casing and screen by over drilling the hole about 1 to 2 m and filling the extra
depth with concrete or gravel.
23.9 DEVELOPMENT OF TUBE WELL

23.9.1 The drilled well shall be developed by any of the methods specified in IS 11189: 1985 depending
upon the site conditions in order to get maximum sand free yield. The development process shall be
continued until the stabilization of sand and gravel pack has taken place.

23.9.2 The development shall be started as far as possible, from the bottom of the screen because
with this the compaction takes place as the work progresses upwards and the overlaying material
can move downwards, without much possibility of bridging and should a bridge develop, the
development action would usually break it up.
23.9.3 The development of the tubewell by over pumping should be done at 15 percent to 25 percent
higher discharge than the expected discharge from the tubewell, The final discharge should be free
from sand with a maximum tolerance of 20 parts of sand in one million parts of water by volume after
20 minutes of starting the pump.
23.9.4 In case of tubewell for drinking water, the discharge shall be totally sand free. If the discharge
is not sand free after 20 minutes of starting the pump, the well shall be redeveloped. In case the
discharge is still not sand free even after re-development, the pump set of lesser discharge capacity
may be installed to get sand free water suitable for drinking. The turbidity and hardness of water of
wells used for drinking purposes, shall be as specified in IS 10500: 1983.
23.9.5 Methods of Development:

23.9.5.1 Numerous methods of development are available. An important factor in any method is that
the development work be started slowly and gently and increased in vigor as the well is developed.
All but one method of well development require the application of sufficient energy to disturb the
natural formation or filter pack so as to free the fines and allow them to be drawn into the well, and to
cause the coarser fractions to settle around and stabilize the screen. This is usually accomplished
by the, surging of water into and out of the well and the formation. The exception is hydraulic jetting;
which depends upon a high velocity water jet discharging through the screen. The jets disturb both-
filter and formation and the water, following the path of least resistance, returns to the well above
and below the jets, carrying the fines into the well.
23.9.5.2 Determination of the adequacy of development is largely a matter of experience and judgment
but as a general rule if interrupted over pumping or raw hiding is used as a final method of development
the degree of development may be estimated from sand samples on each resumption of pumping
On initiation of interrupted pumping, samples shall be taken as frequently as possible as soon as
discharge starts at each new rate of pruning. Sampling of this type at each rate of discharge will
show the time required for maximum sand content to occur and will serve as a guide to subsequent
sampling and development.
23.9.5.3 Shortly after the period in which maximum sand content Occurs in the discharge for each
new rate of pumping, the discharge will become practically sand free until the well is again surged. As
raw hiding continues, the maximum amount of sand content will decrease at each discharge time
interval until water of low sand content is discharged.
The known methods of well development are listed as follows:

(a) Over pumping,
(b) Compressored air,
(c) High velocity jetting,
(d) Surge block, and
(e) Explosives.
23.9.5.4 Over Pumping

23.9.5.4.1 Continuous over pumping- The simplest and most common method is removing fines
from the formation close to the well screen is by over pumping. By this it is meant, pumping the well
at higher capacity than it will be pumped when in regular service say not less than 50 percent above
the designed discharge.

When the water is pumped out of the well, there is a tendency of the sand to move in the direction
of the well end, and with steady pull in this direction, the finer sand grains will wedge against each
other and bridge across openings or voids between coarse grains to a very considerable degree.
The only way in which this can be prevented is by ‘back washing’ which is keeping the water as
agitated as far as possible. The method consist in starting and stopping the pump intermittently to
produce relatively rapid charges in the pressure heads in the well. This shall be done more effectively
with the help of turbine pumps.
The pump is operated with the fullest capacity until it has produced maximum drawdown. It
is then stopped, the water recedes rapidly out of the column of the pump and the well is permitted
to return to its normal static water level. The procedure is repeated many times until the well is
sand free.
Note:- Care shall be taken not to start the pump when the shaft is rotating in reverse direction, as this
is likely to cause damage to the pump shafts.
23.9.5.4.2 Interrupted over pumping - The development process shall include development by
interrupted pumping. The pumping shall be done with a pump capable of pumping at rates up to two
times the design capacity. The pumping should be carried out in at least five steps. These steps shall
include pumping with no check valve or foot valve present. Pumping shall be conducted in five minute
cycles, and shall continue a minimum of two hours or until such time as acceptable standards are
attained.
23.9.5.5 Compressored Air- One of the most commonly used method of developing a tube well is
by compressed air. It shall be used either by back-washing method or by open well or surging method,
23.9.5.5.1 Back Washing Method:

23.9.5.5.1.1 In the back washing method a 3-way valve is turned to deliver air down the air-line, with
the air cock usually open. This pumps water out of the well through the discharge pipe. When the
water becomes clear, the supply of air is cut off and the water in the well is allowed to regain its static
level. The air cock is then closed and the 3-way valve is turned, so that the air supply is directed
down the bypass to the top of the well. This forces the water down out of the casing and back through
the screen, breaking down the ‘Bridge’ of the sand grains When the water has lowered to the bottom
of the drop-pipe, it will not go further, because the air will escape out through the pipe.
23.9.5.5.1.2 When the air is heard escaping out of the discharge pipe, or when the pressure stops
increasing, the supply of air is cut off, and the air cock is opened again to allow the water to reach
static level. The 3-way valve is turned and the air supply again directed down the air line to pump the
well. This procedure is repeated until the well is thoroughly developed. It is advisable to run a bailer,
if practicable. for final cleaning of the well before installing the pump.
The diameter of the drop pipe is usually kept about 5 cm less than that of the well pipe and that
of the air line usually varies from 2 to 6 cm.
The hook-up of the equipment for closed well method is shown in Fig. 23.11.
23.9.5.5.2 Open well method:

23.9.5.5.2.1 This method of development is a combination of surging and pumping Large volume of
air is released suddenly into the well pipe which produces a strong surging action. Pumping is done
as with an ordinary air lift. The success of this method depends on the skillful application of alternating
the surging and pumping as per requirements of the well.

The necessary equipments for this method of development consists of:
(a) Air compressor with air receiver of adequate size
(b) Drop-pipe and airline in well with suitable means for raising and lowering each independently
of the other.
23.9.5.5.2.2 Normally the well pipe itself is used in place of drop pipe but as the washed material has
also to be pumped out along with the water, if required a separate discharge/educator pipe may be
used so that velocity of water pumped out may be sufficiently great to carry with it all the clogged
material from the well. Use of drop pipe becomes necessary in case of deep wells:
(a) Flexible high pressure hose and pipe line to connect between tank and airline in well
(b) The compressor should be fitted with unloaded and the tank must have a relief valve to
safeguard against accidental overloading and
(c) Miscellaneous small fitting, such as pressure gauge and a quick-opening valve at the outlet
of the tank.
23.9.5.5.2.3 In order that development by this method may be fully successful, it is necessary to
have a ratio of submergence of at least 60 percent. The efficiency of development reduces rapidly
with submergence less than 80 percent should the air line be too deeper submerged in proportion to
the net height of the lift, an uneconomically high pressure will be required to force the air out.
The discharge of the compressor shall be piped direct to the tank without any valve in the line.
The discharge from the tank to the well shall be the full size of the airline in the well, or if long, the next
larger size, and shall be fitted with a quick opening valve near the tank. A high-pressure hose is used
between the discharge pipe from the tank and the airline in the well. This hose shall be at least 4.5 to
6 m long to allow sufficient space for moving the drop pipe and air line up and down.
Before blowing water or drilling mud out of the well, the air-lift shall be operated slowly for a time
to make sure that the screen is sufficiently open so that water will come into the well freely, otherwise
damage to the screen may take place.
23.9.5.5.2.4 At the start of development the drop pipe is lowered within 600 mm or so of the bottom
of the screen, and the airline is placed, so that it is inside the drop pipe by 300 mm or more. If there
is plenty of submergence airline needs to be lowered only for enough to get 60 or 70 percent sub-
mergence. The air is turned into the airline and the well is pumped in the manner of a regular air lift,
until the water appears to be free from sand. The valve between the tank and the airline is then
closed, allowing the tank to be pumped full of air up to required pressure. In the meantime, the airline
is lowered so that it is 300 mm or so below the drop pipe. The quick opening valve is then thrown
open, allowing the air in the tank to rush into the well. There will be a brief but forceful surge of the
water and then a ‘head’ of water will ‘shoot’ partly from the drop pipe. If the airline is pulled back into
the drop pipes as soon as the first heavy load of air has been shot into the well, it will produce a
strong reversal of flow up the drop pipe which will quite effectively agitate the water-bearing formation.
23.9.5.5.2.5 The well is then allowed to pump as an air lift for a short time, and then another ‘head’ is
shot. repeating until the absence of further sand, etc, shows that the development is complete at this
point. This procedure may be repeated in stages at convenient places in the screens, which will
complete the work and clean out loose sand which might have settled at the bottom of the well.
The compressor shall be capable of developing sufficient pressure to overcome initial head of
water in the air line. The recommended size of pumping pipe, and the size of the airline with the
pumping rate is given below for guidance.

Pumping Rate Size of Pumping Pipe Size of Airline
Litre/min mm mm
450-700 100 30
700-900 125 40
1125-1800 150 50
1800-3200 200 65
This method has its own limitations where the yield is very weak and the draw down rapid or where
submergence is low.
Hook-up for open well method is shown in Fig. 23.12.
23.9.5.6 High Velocity Jetting:

23.9.5.6.1 Jet development is a recent addition to other common methods of developing wells. In this method
water jets projected at high velocity out through well screen openings effectively loosen fine sand, silt and
drilling mud from the water bearing formation. The loosen material moves inside the well screen and is
removed from the well by pumping or bailing.
The jetting tool consists of an attachment fitted with two or more evenly spaced horizontal nozzles having
6.2, 9.5 or 12.7 mm orifices. The bottom of the tool is closed and the depth of setting, the choice of the nozzle
depends largely on the capacity of the high pressure pump. The main item of equipment needed for this
method are the jetting tool, high pressure pump, hoses and connections, 5 cm dia pipe line and a source of
water. The size of the pipe for feeding water to the nozzles should be large enough to keep friction losses to
a reasonable value. It generally ranges from 4.0 to 7.5 cm depending upon the length of the pipe and discharge
it has to carry.
The diameter of the jetting tool shall be about 25mm less than the inside diameter of the screen. The
normal jet discharge ( per nozzle) and velocity is as indicated below:
Nozzle Pressure 7kgf/cm2 Pressure 14kgf/cm2 Pressure 17.6kgf/cm2
Orifice Velocity Discharge Velocity Discharge Velocity Discharge
mm m/sec lt/min m/sec lt/min m/sec lt/min
6.20 33.50 17 46 118 55 90
9.50 33.50 172 46 255 55 280
12.70 33.50 305 46 450 55 500
23.9.5.6.2 The procedure consists of operating a horizontal water jet inside the well in such a way that the
high velocity stream of water shoot out through the screen openings. By slowly rotating the jetting tool and
gradually raising and lowering it, the entire surface on the outside of screen gets the vigorous action of the jet.
Fine sand, slit and clay are washed out of the water-bearing formation and the turbulence created by the jet
rings these fine materials back into the well through screen openings above and below the point of operation.
Wherever possible, it is desirable to pump the well lightly at the same time as the high velocity jet is working
by using air compressor. The water so pumped can be reused for jet-development after pumping it into a
setting tank.
23.9.5.7 Surge Blocks:

23.9.5.7.1 An effective method for developing the well is surging created by the rapid up and down motion of a
plunger, operated in the casing pipe provided above the screened portion of the well. The rapid motion of the
plunger causes forceful reversal of the movement of water, which prevents the bridging of finer particles. The
repeated application of the surging force draws fine particles from the aquifer and thus porosity and permeability
of the zone around the screen is increased.
A surge plunger is most used tool for development particularly in wells drilled by cable tool methods and
tubewells of natural gravel pack well where strainers have been used.

23.9.5.7.2 Yet there in another method which is called ‘Swabbing’ in which the swab is lowered into the
casting to any selected point and then pulled upwards to produce an inward flow. Swabbing therefore, helps in
taking out the fine material drill in consolidated rock aquifers, but are very seldom used in screened wells.
Sand pumps may also accomplish effective development of shallow wells with cable tool methods.
23.9.5.7.3 Where the aquifer contains many clay streaks use of plunger block is not recommended because
this can cause the clay to plaster over the strainer surface and thus clog the strainer resulting in reduced
discharged. Sometimes the strainer give away due to high differential pressure when the strainer is clogged
with clay.
After the sand has been drawn in by the surge block the well is cleaned by using a hailor and the process
is repeated till the well is totally sand free. Total time involved for developing may range from four hours for a
small well to 3-4 days on large well with longer screen.
The size of the plunger shall be kept such that it does not fit in the casing pipe. It shall be able to pass
within the pipe and its fittings freely. The plunger may be run on a continuous string of pipe or a part string with
a cable adopter at the top. The surging plunger is lowered into the casing about five metres below the water.
The movement of the plunger should be restricted in the portion above the screen in the casing pipe. After
lowering, it is stroked to produce surging effect. The stroking may come off the beam of a percussion drill or
off a cat head or by hand tripping. Some time, hoisting mechanism is used for this. Initially, the surging shall
be stated slightly and gradually increased till it reaches the maximum limit of the system. Through bailing
between the runs of the plunger is very important for efficient development. The surging and bailing out is
carried out till little sand is driven into the well. In case of wells with long screens, surge plunger may, however,
be operated inside the screen for effective development. A typical surge block has been shown in Fig. 23.13.
23.9.5.8 Explosives - These are sometimes employed to develop and enlarge cervices and fissures in tubewells
drilled in hard rocks. Charges of 14 to 230 kg are used according to the hardness of the rock and the depth at
which the charge is to be detonated.
23.9.6 Criteria for Proper Development of Tubewells - Development work is an essential operation in the
completion of drilling job. It consists of steps to remove the finer material and opening up the passage in the
formation so that water can enter the well through the screen more freely. Proper development is said to have
been satisfactorily done when:
(a) The stabilization of the sand formation has taken place, that is, there is no further sinking of gravel
and the discharge is sand free; and
(b) Permeability of the formation is increased by removing finers utilizing proper development method.
23.9.7 After completion of development by over- pumping, the well shall be tested for its performance that is
yield characteristics and efficiency. This shall be achieved by conducting a step draw down test-determine
draw downs at the end of the hour by pumping at 3 to 4 different rates of discharge.
23.10 DISINFECTION
23.10.1 The well shall be disinfected after completion of test for yield. All the exterior parts of the pump
‘coming in contract with the water shall be thoroughly cleaned and dusted with powdered chlorine compound.
In fact it should be disinfected every time a new pump is installed or the one replaced after repairs.
23.10.2 A stock solution of chlorine may be prepared by dissolving free chlorinated lime. For obtaining an
applied standard concentration of 50 ppm. One litre of the stock solution should be used to treat 300 litres of
water.
23.10.3 In -case of water-wells for drinking water purposes, the quality of water should be as laid down in IS
10500: 1983.

23.11 GROUTING AND SEALING
23.11.1 Grouting and sealing of tubewell may be done, if required by the owner, depending upon the
site conditions and quality of the discharge of the strata encountered. To ensure that the grout will
provide a satisfactory seal, it should be applied in one continuous operation. Sealing of the tubewell
may be done by grouting the annular space between bore and the housing pipe, thickness of grouting
depending upon the quality of water. In case of tubewells for drinking purposes, grouting and sealing
shall always be done to ensure safe sanitary conditions.
23.11.2 It is desirable to plan an oversize bore hole of 7.5 to 15 mm more than the diameter of the
well casing to an adequate depth during the design of well itself. The depth to be grouted varies with
geologic and site conditions but a depth of 3 to 4.5 m from the surface is generally adequate.
23.11.3 Surface Apron -An apron around the well and sloping away from it protects the well from
pollution caused by contaminated water flowing back into it and prevents muddy pools of standing
water forming around the well.
23.12 HANDING OVER OF THE TUBEWELL

23.12.1The tubewell should be handed over to the owner in a complete shape. The housing pipe
should be closed by a well cap for the .period between the completion of the tubewell and the
installation of the pump set.
23.12.2 The following information shall be .furnished by the drilling agency on completion of the
tubewell:
(a) Total depth of tubewell drilled,
(b) Strata chart of the tubewell indicating different type of soil formations met with at different
depths and indicating the depth of each type of soil formation,
(c) Samples of strata collected, neatly packed and correctly marked in sample bays,
(d) Position of every joint in well assembly,
(e) Method used for development,
(f) Total hours of development done,
(g) Developed discharge in LPS,
(h) Discharge is totally sand free or presence of sand particles is there,
(i) P.P.M. and turbidity after development,
(j) Pumping water level at developed discharge, and
(k) Static water level.
23.12.3 A typical proforma is given in Annex A to furnish the details given in 23.12.2.

Annex A
INFORMATION TO BE FURNISHED BY DRILLING AGENCY TO OWNER ON COMPLETION OF

TUBEWELL (As per para 23.12.2)
1. Agency drilling the tubewell.............................

2. Location of the tubewell...................................
3. Method of drilling adopted...............................
4. Date of starting.................................................
5. Date of completion.........................................
6. Pilot hole or test hole.......................Bit siz.........
Bit type........Hours..................from....................to........
7. Coring done...............................Bit size...............bit..............from..........to...........
8. Reaming.....................Bit size...............Bit type......................Hours....................from......to......
9. Lithological data.
From To Formations
..................... ........................ .....................
..................... ........................ .....................
10. Total depth of tubewell drilled................................

11. Assembly of production well........................size...........length...................Type.........
Perforation per meter.............................................
Housing pipe.............................................................
Blind pipe...................................................................
Strainer.....................................................................
Bail plug....................................................................
12. Top of tubewell above / below ground level....................................
13. Size of gravel........................Quantity used before
development........................Quantity used during development.............
14. Method used for development.........................................................
Total hours of testing.......................................................................
15. Development discharge..................................................................
16. Turbidity......................................................................
17. Further details appended :
(a) Samples of strata, neatly packed in sample bags.
(b) Chart of pipe assembly lowered, and
(c) Results of mechanical analysis of samples of unconsolidated strata.
18. Remarks :
Owner ...................................Driller.

CAVITY WELL & TUBE WELL
Sub Head : Rain water Harvesting & Tubewells
Clause : 23.2

Ǥʹ͵Ǥͳȋ
Ȍ
Ǥʹ͵Ǥʹȋ Ȍ

Ǥʹ͵Ǥ͵ȋ
Ȍ
Ǥʹ͵ǤͶȋ
Ȍ

TUBE WELL & BORE WELL
Clause : 23.2.2 & 23.2.3

Ǥʹ͵Ǥͷȋ
Ȍ
Ǥʹ͵Ǥ͸


AUGERS
Clause : 23.3.1

Ǥʹ͵Ǥ͹

Ǥʹ͵Ǥͺ
ǯ


SIMPLE JETTING RIG
Clause : 23.3.2

Ǥʹ͵Ǥͻ


TYPICAL DETAILS OF TAPER REDUCERS, WELL CAP, V-NOTCH PLATE,
CENTRALIZING GUIDE, BAIL PLUG AND CLAMP
Clause : 23.4.1

Fig. 23.10 : Typical Details Of Taper Reducers, Well Cap, V-Notch Plate, Centralizing Guide, Bail Plug And Clamp

CLOSED WELL DEVELOPMENT WITH AIR COMPRESSOR
Clause : 23.9.5.5.1
Ǥʹ͵Ǥͳͳ


OPEN WELL DEVELOPMENT WITH AIR COMPRESSOR

Clause : 23.9.5.5.2

Ǥʹ͵Ǥ


SURGE BLOCK

Clause : 23.9.5.7

Ǥʹ͵Ǥͳ͵


SUB HEAD : 24.0
CONSERVATION OF HERITAGE
BUILDINGS
1241
CONTENTS
24.1 Raking Of Joints 1246
24.2 Double Scaffolding System (Cup Lock Type) 1249
24.3 Chemical Cleaning of The Stone Masonry 1249
24.4 Anti-Fungal Wash of The Stone Masonry 1250
24.5 Ruled / Flush Pointing on Red Sand Stone Work 1251
24.6 Ruled / Flush Pointing on White Sand Stone 1253

Masonry
24.7 Stone Surface Strengthening by Using Chemicals 1254
24.8 Reduction of Moisture Absorption by Stone Masonry 1255

by Application Of Sealers
1243 SUB HEAD 24.0 : CONSERVATION OF HERITAGE BUILDINGS


1. IS 533 Gum Spirit of Turpentine (Oil of Turpentine)

24.0 CONSERVATION OF HERITAGE BUILDINGS
24.0 The rich cultural heritage of the country ranging over millenniums is testimony to our glorious
history and one of the most ancient civilizations of the world. These historical buildings and monuments
located through length and breadth of the country symbolizing the social, religious and cultural
developments during different periods of history are made of different building materials having
specific structural design. The built cultural heritage located in different parts of the country exposed
to different climatic conditions is equally varied in its range and content. There are rock- shelters;
rock- cut caves, monasteries made of adobe, brick structures, monuments made in ashler masonry,
temple, fort, palatial buildings of Mughal architecture and so on. In addition there are structures
buried in the earth, some of which have been exposed.
The ravages of time and various weathering agencies through physical - chemical processes
by interaction between the environment and mineral compounds of the substratum have been
responsible for the deterioration of built cultural heritage. The synergic human factors combined
with changes in the environmental scenario around monuments located in the urban and semi
urban areas have added new challenges in the conservation field. In view of diverse nature of
problems and their varying magnitude in different cases, the maintenance and conservation of
monuments is a challenging job.
Ethics of conservation:
A careful preservation and protection of something is its conservation. The objective of
conservation is to prolong the life of cultural inherited property and if possible, to clarify the artistic
and historical message therein without the loss of authenticity. The Engineer in Charge related to the
conservation should have a flexible pragmatic approach based on cultural consciousness, proper
training, sound judgment and a sense of proportion with an understanding of the community needs.
Conservation of cultural heritage:

It involves protection and restoration using “any methods that prove effective in keeping that
property in as close to its original condition as possible for as long as possible.
Conservation of cultural heritage applies simple ethical guidelines:
• Minimal intervention;
• Appropriate materials and reversible methods;
• Full documentation of all work undertaken.
Aim of Conservation:
Aim of conservation is not to produce what has been defaced or destroyed but to save what is left
from further injury or decay and to preserve it as a national heirloom.
Basic Principals of Conservation of Heritage Structures:

Approach to the conservation works to be carried out is laid down as under:
(i) Hypothetical restorations are unwarranted, unless they are essential for the stability of a
building/ structure.
(ii) Every original member of a building/ structure should be preserved intact and dismantling
and reconstruction should be undertaken only if a structure cannot be otherwise maintained.
(iii) Restoration of carved stone, carved wood or plaster molding should be undertaken only if
artisans are able to attain the excellence of old.

24.1 RAKING OF JOINTS
24.1.1 Preparation of Surface:
The purpose of surface preparation is to remove all kinds of loose material, debris, leaves, paper
etc. from the surface where raking of the joints is to be carried out for re-plastering or re-pointing the
stone masonry as the case may be.
24.1.1.1 The surface should be cleaned with brooms to remove of any loose material like dirt and
dust. Now, the surface should be cleaned by using high pressure Jet machines having dual benefit of
removal of the loose material and softening of the mortar in the stone masonry. Every effort should
be made to avoid dust nuisance.
24.1.2 Safety:
Contractor shall be advised to ensure that all workers should wear helmets, safety belts, proper
shoes, tight clothes etc. while working at all heights including working on domes etc. Every effort
should be made to avoid free falling of the material and necessary protection should be provided
along the scaffolding (if any).
Care shall be taken by the agency to avoid any damage to the heritage building. If any structural
or aesthetic damage is caused to the building the same shall be made good by the agency at its own
cost and nothing extra shall be paid for this.
24.1.3 Tools and Plants (T&P)

Agency will provide all the requisite tools and plants like hammer & chisel for manual raking and
Power or Pneumatically driven mechanical mortar raking equipments of approved manufacturers’ as
per site conditions and as per directions of the Engineer-in-charge.
The agency will take prior permission of the Engineer-in-Charge to use Power or pneumatically
driven mechanical mortar rakers depending upon the noise level that can be approved in the area
where work is to be carried out. The work should be carried out in most professional manner so that
no interference is caused to the working of various offices/residences housed in or in the vicinity of
the heritage building.
Mechanical Jet Spray machines of requisite power shall be procured by the Agency and also
shall make own arrangement of the water for the purpose.
To ensure efficient and effective functioning, all T&P must be checked on-site at regular intervals
and work must not hold up for want of repairs of the T&P.
24.1.4 Skilled Site Personnel

Only skilled workers shall be employed by the contractor. They must possess knowledge of working in
heritage buildings and must have required special training and/or practical experience in executing
such works. At least the supervisory staff and major workers should have requisite expertise in the field.
24.1.5 Scaffolding
Scaffolding shall be strong to withstand all dead, live and impact loads which are likely to come on
them. Scaffolding shall be provided to allow easy approach to every part of the work.
24.1.5.1 Double Scaffolding: Where the joints in the masonry of heritage building are to be exposed
by raking, manual or mechanical, double scaffolding system (cup & lock type) shall be provided in
the interior as well as exterior side of the building wherever it is feasible/ required to provide the
scaffolding system.The scaffolding system shall be stiffened with bracings, runners, and connectors
etc. to secure it to the building. Size of the members shall be dependent upon the height at which
raking of the joints is to be done.

24.1.6 Raking of Joints
Proper working space/platform shall be provided to the workers by providing scaffolding (if
required) so that raking of the joints could be done easily. The surface where raking of joints is to be
done,shall be clearly marked with chalk or any other material, so that it can be easily distinguished.
Raking with hand tools like hammer and chisel shall be resorted to in case the location is not
easily accessible for mechanical equipments, sufficient power supply is not ensured or the area is
too small to be economical for mechanical raking.
Raking of joints should progress from one end to other first raking the one horizontal joint at a
time to the requisite depth as decided by the Engineer-in-Charge. Then next horizontal joint is taken
up and so on. Once all horizontal joints are raked up vertical joints shall be raked from either ends.The
raked joints are then cleaned by brushing and watering.
The debris/rubbish shall be collected in most professional manner and disposed of to the dumping
ground up to 50metres lead or as per direction of the Engineer-in-Charge.
The whole process shall be considered complete if approved from the Engineer-in-Charge.
24.1.7 Measurements
1. Length and breadth shall be measured correct to a cm and its area shall be calculated in
square metres up to two places of decimal.
2. For jambs, soffits, sills etc. for opening not exceeding 0.5 sqm each in area, ends of joists,
beams,posts, girders, steps etc. not exceeding 0.5 sqm each in area and opening not
exceeding 3 sqm each deductions and additions shall be made in the following way, in case
of raking on external face only.
(a) No deduction shall be made for ends of joists, beams, posts etc. and openings not
exceeding 0.5Sqm each, and no addition shall be made for reveals, jambs, soffits,
sills, etc. of these openings.
(b) Deductions for openings exceeding 0.5 sqm but not exceeding 3 sqm each shall be
made as follows and no additions shall be made for reveals, jambs, soffits, sills, etc.
for these openings.
(c) When both the faces of the wall are raked deduction shall be made for one face only.
(d) When only one face is raked deduction shall be made from one side of frame for
doors, windows, etc. on which the width of the reveal is less than that on the other
side, but no deduction shall be made from the other side.
(e) Where width of reveals on both faces of wall is equal, deduction of 50% of area of
opening on each face shall be made from the raked area.
(f) For opening having door frame equal to or projecting beyond thickness of wall, full
deduction for opening shall be made from each pointed face of wall.
3. In case of openings of area above 3 sqm each, deduction shall be made for the openings,
but jambs, soffits and sills shall be measured.
24.1.8 Rates
The rate shall include the cost of all materials and labour/equipments involved in all the operations
described above except Scaffolding which if required and provided shall be paid for separately).

24.2 DOUBLE SCAFFOLDING SYSTEM (CUP LOCK TYPE)
The specifications shall be same as Clause 14.33 read with Clause 5.2.3.2 of CPWD
Specification 2019.
24.3 CHEMICAL CLEANING OF THE STONE MASONRY

Clean and well maintained heritage buildings are always admired by all. With the passage of
time, staining of heritage buildings are caused by a number of elements such as metals, asphalt,
smoke, oil, grease, bird droppings, organic growth etc. due to which they appear neglected. In order
to maintain the buildings important and attractive from heritage point of view these need to be cleaned
of the stains. It should however be kept in mind that the heritage/historic buildings are there not for
our use and enjoyment but also for the future generations. The overriding consideration should
always be to limit the cleaning to the bare minimum. Much damage has been done to the building by
over cleaning. The gentlest means of cleaning should therefore be adopted.
Cleaning help to preserve masonry by eliminating heavy accumulation of surface dirt which stop
evaporation of moisture from within the masonry, thus, from within the masonry. Careful cleaning
procedure can remove harmful atmospheric deposits and help to slow the decay. Careful cleaning
can make the existing damage more visible therefore, corrective measures can be taken.
24.3.1 Material
Cleaning the stone masonry can be done by the following three ways:
Water cleaning
Chemical Cleaning
Abrasive Cleaning
All these methods can be combined to attain optimum results. The selection of materials to be
used depends upon the type of masonry.
24.3.1.1 Acidic Cleaners:

Hydrofluoric acid (HF) is the only acid that does not form dangerous soluble salts during the
cleaning process. However, acidic cleaners as suggested by ASI or as approved by Engineer-in-
Charge can be used. These are exceptionally dangerous to use and have to be handled with extreme
care. Gloves and full body protection must be worn. These should never be used at concentrations
exceeding 5 percent. Acidic cleaners are used on Strong sand stones. These should never be used
on polished stones like granite, glass and marble.
24.3.1.2 Alkaline Cleaners

Ammonium Hydroxide (Ammonia in water solution) is an alkaline cleaner which can be used on
calcareous material like marble. Many other commercial cleaners are based on Sodium Hydroxide
(Caustic Soda) are available in Market can also be used.
24.3.1.3 Abrasive Cleaners

This involves wet or dry sand or grit blasting, dry brushing and manual abrasion. Excessive
pressure and lack of precision and control may result in the destruction of the surface. Hence, wet
grit/sand blasting methods should be used with skill and care to get the desired results.
24.3.2 Tools and Plants

High Pressure Jet Machine with accurate Pressure regulators and gauges is required to produce
nebulized water mist through its nozzle, plastic or soft bristle brushes, brooms etc. The water pressure
should be controlled by gauges and regulators depending upon the type of stone.

24.3.3 Chemical Cleaning
The chemical cleaning should first be tested on a small area to establish the amount of cleaning
required and feasibility of the system and optimal strength and combination of various components.
The test area should be so selected that it represents the requisite soiling or staining. The occupants
of the building should be forewarned. Sufficient provision for safe scaffolding, plant, clean water
supply, safe storage of the materials and removal of debris be made at site before commencement of
the chemical cleaning. Glass, painted and polished surfaces should be protected by applying peelable
plastic compound, polythene sheets or hardboard sealed at the edges.
The washing should start by mixing requisite quantity of Ammonia chemical not more than 5%
concentration or Teepol or any other chemical approved by ASI and/or Engineer-in-Charge mixed
with fine sand/silica. The pressure of the Machine should be maintained so that misting (which uses
little water) is achieved. The spray should be applied at an angle so that it removes the stains easily.
Right Angled jets destroy the surface, hence, better to avoid. The jet should be applied till the
requisite cleaning is not obtained.
After Chemical cleaning the surface should be rinsed with clean water. Efforts should be made to
remove all the chemicals to avoid damage to the masonry. Any splashes on doors, windows, polished
etc. shall be made good by the agency at own cost and nothing extra shall be payable on this
account.
24.3.4 Measurements
Length and breadth of the surface of stone masonry cleaned shall be measured correct to a cm
and its area shall be calculated in square metres up to two places of decimal. No deduction is to be
made for any openings in the range of 0.5 Sqm and nothing extra shall be payable for providing
protective films on doors, windows etc.
No deduction shall be made for the jali work as well.

Nothing extra shall be paid for ornamental work of any nature up to a radius of 3.00 Metre.
24.3.5 Rates
described above (Scaffolding, if required to be provided, shall be paid for separately).
24.4 ANTI-FUNGAL WASH OF THE STONE MASONRY

Bio-deterioration prevailing in stone monuments and historical buildings is a well recognized
problem existing in tropical regions or environment like India, where due to environmental factors in
the form of high temperature, high relative humidity levels and also to the some extent heavy rainfall
causes the bio-deterioration and bio-weathering favour the growth and simultaneously allows living
various organism (micro and macro) to remain on stone surfaces because there are no natural or
environmentaltreatment is found so far to protect the stone unless and until the monuments are
given chemical treatment for sustainability.
In order to avoid attack by fungus on the heritage buildings anti-fungal wash treatment is done
using 3% solution of sodium penta-chloro-phenate of reputed brand and manufacturer on cleaned
stone masonry. Sodium penta-chloro-phenate is a chlorine compound having herbicidal, fungicidal
and bactericidal applications.
24.4.1 Materials:
Sodium penta-chloro-phenate is a white or tan, powdered solid. It is soluble in water and may
burn, but it is not easily ignited.Sodium penta-chloro-phenate of approved brand and manufacture
as approved by the Engineer-in-Charge shall be procured for application as biocide over stone
masonry in heritage/historical buildings.

24.4.2 Application
The Sodium penta-chloro-phenate shall be applied with spray guns avoiding contact with bare
skin altogether. The chemical should be diluted such that it should not be have concentration more
than 3% in the solvent.
During spraying the spray gun shall be held perpendicular to the surface of the stone masonry
and shall be passed over the stone masonry in a uniform sweeping motion. Different air pressures
and fan adjustment shall be tried so as to obtain the best application.
24.4.3 Precautions:
Sodium penta-chloro-phenate may be toxic by ingestion, inhalation and skin absorption. Requisite
safety precautions must be taken while applying this chemical. Good quality mask shall be borne by
the worker to protect from chemical poisoning.
24.3.4 Measurements
Length and breadth of the treated area shall be measured correct to a cm and its area shall be
calculated in square metres up to two places of decimal. No deduction is to be made for any openings
in the range of 0.5 Sqm and nothing extra shall be payable for providing protective films on doors,
windows etc.
No deduction shall be made for the jali work as well.
Nothing extra shall be paid for ornamental work of any nature up to a radius of 3.00 Metre.
24.3.5 Rates
described above. Scaffolding, if required and provided, shall be paid for separately.
24.5 RULED / FLUSH POINTING ON RED SAND STONE WORK

24.5.0 Pointing shall be as per existing pattern or as decided by the Engineer-in-Charge. A sample
patch shall be prepared for pointing and got approved from the Engineer-in-Charge. The further
work shall be taken up only after the approval of the sample work by the Engineer in charge. The
work executed should match exactly to the sample patch.
24.5.1 Scaffolding
For all exposed Red Sand stone work independent double scaffolding having two sets ofvertical
supports shall be provided. The supports shall be sound and strong tied together with horizontal
pieces over which scaffolding planks shall be fixed.For all other work in building, single scaffolding
shall be permitted. In such cases, the inner end ofthe horizontal scaffolding pole shall rest in a hole
provided only in the header course for the purpose.Only one header for each pole shall be left out.
Such holes for scaffolding shall, however, not to be allowedin pillars/columns having width less than
one metre, or immediately near the skew backs of arches. The holes left in masonry works for
scaffolding purposes shall be filled and made good before plastering.
The scaffolding material will be stacked at designated place decided by the Engineer-in-Charge
and shall be removed after execution of the work and nothing extra shall be payable on this account.
The scaffolding shall be got approved from Engineer-in-Charge before start of work.
.
Joints shall be raked out as per item No. 24.1

24.5.3 Mortar
Mortar should be weaker than the masonry to accommodate movement in heritage buildings to
the extent possible. The mortars used in the old heritage buildings were usually lime based being
water resistant and flexible. Mortar mix as specified in DSR item 3.19 shall be used for reference
purpose only. It should be lime, Surkhi (50% red and 50% light yellow) and marble dust in proportion
of 1:1.5: 0.5. However, efforts shall be made to duplicate original mortar mix and match the existing
mortar joint.

24.5.4.1 The surface should be thoroughly cleaned and wet before application of the mortar. It
should be ensured that adjoining stones should also be made wet so that the mortar dries slowly. If
required, tarpaulin shall be used to make the surface shady during sunny weather. The mortar shall
be pressed into the raked-out joints carefully with a pointing trowel, either flush, sunkor raised,
according to the type of pointing required. The pointing lines shall be truly horizontal and vertical
except where the joints are slanting in the existing heritage structural masonry. Lines of joints from
different directions should meet neatly at the junctions instead of crossing beyond.
The mortar shall not be spread over the corner, edges or surface of the masonry. The pointing shall
then be finished with the proper tool, in the manner described below:
24.5.4.2 Flush Pointing: The mortar shall be pressed into the joints and shall be finished off flush
and level with the edges of Red Sand stone masonry, so as to give a smooth appearance. The edges
shall be neatly trimmed with a trowel and straight edge.
24.5.4.3 Ruled Pointing: The joints shall be initially formed as for flush pointing and then while the
mortar is still green, a groove of shape and size as per existing pattern or as shown in drawings or as
instructed by the Engineer-in-Charge, shall be formed by running a forming tool, straight along the
centre line of the joints. This operation shall be continued till a smooth and hard surface is obtained.
The vertical joints shall also be finished in a similar way. The vertical lines shall make true right
angles at their junctions or to the existing pattern of the heritage building true with the horizontal lines
and shall not project beyond the same.
24.5.4.4 Cut or Weather Struck Pointing: The mortar as specified above shall first be pressed into
the joints. The top of the horizontal joints shall then be neatly pressed back about 3 mm or as
directed by the Engineer-in-Charge, with the pointing tool so that the joints are sloping from top to
bottom. The vertical joints shall be ruled pointed. The junctions of vertical joints with the horizontal
joints shall be at true right angles or to the shape of the existing heritage building structure.
24.5.4.5 The superfluous mortar shall then be cut off from the edges of the lines and the surface of
the Red Sand Stone masonry shall also be cleaned off all mortar. The finish shall be such that the
pointing is to the exact size and shape required and the edges are straight, neat and clean.
24.5.5 Curing
The pointing shall be kept wet for seven days. Treated area should preferably be covered/ wrapped
with hessian cloth, which is kept wet for the entire curing period. During this period, it shall be suitably
protected from direct sun and all damages.
24.5.6.1 Length and breadth of the area of stone work treated shall be measured correct to a cm and
its area shall be calculated in square metres up to two places of decimal.
24.5.6.2 The various types of pointing for example, struck, keyed, flush, tuck, etc. shall each be

24.5.6.3 For jambs, soffits, sills etc. for opening not exceeding 0.5 sqm each in area, ends of joists,
beams, posts, girders, steps etc. not exceeding 0.5 sqm each in area and opening not exceeding 3
sqm each deductions and additions shall be made in the following way, in case of pointing on external
face only.
(a) No deduction shall be made for ends of joists, beams, posts etc. and openings not exceeding
0.5 sqm each, and no addition shall be made for reveals, jambs, soffits, sills, etc. of these
openings.
(b) Deductions for openings exceeding 0.5 sqm but not exceeding 3 sqm each shall be made
as follows and no additions shall be made for reveals, jambs, soffits, sills, etc. for these
openings.
(i) When both the faces of the wall are pointed with the same pointing deduction shall be
made for one face only.
(ii) When two faces of wall are pointed with different pointings or if one face is plastered
and other is pointed or plastered, deduction shall be made from the plaster or pointing
on the side of frames for doors, windows, etc. on which the width of the reveal is less
than that on the other side, but no deduction shall be made from the other side.
(iii) Where widths of reveals on both faces of wall are equal, deduction of 50% of area of
opening on each face shall be made from area of pointing or plaster as the case may
be.
(iv) For opening having door frame equal to or projecting beyond thickness of wall, full
deduction for opening shall be made from each pointed face of wall.
24.5.6.4 In case of openings of area above 3 sqm each, deduction shall be made for the openings,
but jambs, soffits and sills shall be measured separately.
24.5.7 Rate
described above. Raking of joints and Scaffolding if required & provided shall be paid for separately.
24.6 RULED / FLUSH POINTING ON WHITE SAND STONE MASONRY

24.6.0 Pointing shall be as per existing pattern or as decided by the Engineer-in-Charge.
24.6.1 Scaffolding
Same as 24.5.1 above.

Joints shall be raked out as per item No. 24.1
24.6.3 Mortar
Mortar mix as specified in DSR item 3.19 shall be used with slight variation to the contents of
Surkhi. It should be lime, Surkhi (15% dark red and 85% light yellow or as approved by the Engineer
in Charge) and marble dust in the proportion of 1:1.5:0.5.

Same as 25.5.4 above
24.6.5 Curing

24.6.7 Rate
24.7 STONE SURFACE STRENGTHENING BY USING CHEMICALS

24.7.0 Deterioration of heritage/historical buildings is caused by weathering conditions like
atmospheric pollution, salty water or winds and effect of pollutants from rainwater. This deterioration
process can be delayed by application of chemical solvents over the surface of the stone masonry.
The solvent/chemical coating enhances the compressive strength of the stone particularly sand
stone. The chemical fill the pores of the stone masonry and creates a protective cover thereby
preventing the absorption of the water containing harmful pollutants.
24.7.1 Material
The most commonly used stone surface strengthening chemical is Ethyl Silicate. Ethyl Silicate
has very good compatibility with stone having silicate-based composition like Sand Stones. The
chemical shall be of approved brand and manufacture. However, the choice of the chemical depends
upon the prevailing climate conditions and type of stone masonry. Therefore, the chemical shall be
got approved from ASI and/or Engineer- in- Charge before application.

The chemical is to be applied with simple painting brushes or with spray gun as decided by the
Engineer-in-Charge.
24.7.3 Surface Application

A sample patch of 5 Sqm or of the size decided by the Engineer-in-Charge shall be prepared to
know the number of strokes/coats required for achieving “apparent refusal”i.e. no further absorption
by the stone masonry.The further work shall be taken up after approval and requisite number of
coats as decided in the test patch shall be applied. The decision of the Engineer in charge shall be
final and binding in this regard.
The chemical should be applied only on clean and dried stone masonry.In no case the surface
should be wet before application of the chemical. As far as possible the chemical should be applied
with brushes as it offers good penetration and good efficiency of the chemical application. The
chemical can be applied with spray gun for sites where time is limited. Where sufficient time is available
brushing offers a good methodology for application of the chemical to desired penetration. Spraying
delivers high quantity of the chemical at a time causing a large runoff and lesser penetration.
The chemicals should be uniformly applied with brushes or spray on the existing stone masonry
until there is “apparent refusal” i.e. no further absorption by the stone masonry. Over deposition of
the chemical at a place shall be avoided altogether. After application of the first coat, second coat
shall be applied once the first is dried or at least a gap of 10 minutes is to be made.
The stone masonry surface where the chemical is to be provided shall be protected from direct
sun light, rain, snow or heavy winds.
24.7.4 Measurements
Measurements shall be same as described in para 24.1.6
24.7.5 Rates
described above. Scaffolding if required & provided shall be paid for separately.

24.8 REDUCTION OF MOISTURE ABSORPTION BY STONE MASONRY BY APPLICATION OF
SEALERS
24.8.0 Mortar and masonry tend to readily absorb water due to their pore and capillary structure.
The damage to the heritage structure can be prevented by application of a water repellent sealer
which reduces the absorption of the moisture by sand stone masonry or mortar.
24.8.1 Materials:
Silanes and Siloxanes are the two most common type of water repellents derived from the silicone
molecule. Silicone is a generic name for a wide variety of polymeric chains constructed around a
molecular backbone of Silicon-oxygen-silicon.
Silanes and Siloxanes are penetrating type sealers which allow the heritage stone masonry to
breathe, moisture vapour to escape while repelling water from the outside. Moreover, these do not
impart any gloss to the stone masonry and there is little change to the appearance of the heritage
structure.
When applied, Silane water repellents penetrate the stone masonry and react chemically with
Calcium Hydroxide (CaOH) to form a hydrophobic, water repellent resin within the pores and on the
surface. Silanes act only if the pH of the stone masonry is high and also must contain Calcium
Hydroxide.
On the contrary Siloxanes react with atmospheric moisture as well as any moisture in the existing
masonry to form the hydrophobic resin. Siloxanes are ideal for stone masonry. However, the type of
chemical to be used shall be approved by ASI and/or the Engineer in Charge.
Silanes or Siloxanes: Silanes and Siloxanes of approved brand and manufacture as approved by
ASI and/or by the Engineer-in-Charge shall be used as per manufacturer’s specifications.
Turpentine: Mineral turpentine i.e. petroleum distillate which has the same rate of evaporation as
vegetable turpentine (distillate product of oleoresin of conifers) shall be used. It shall have no grease
or other residue when allowed to evaporate. It shall conform to IS 533. Turpentine oil recommended
by the manufacturer or as approved by the Engineer-in-Charge shall be used.

Silanes and Siloxanes can be applied with good quality of brush, roller or spray as decided by the
Engineer in Charge.

The surface of stone masonry shall be cleaned properly by using any methods decided by the
Engineer-in-Charge. The surface shall be cleaned for any dirt, dust etc. by application of broom,
vacuum cleaner or any other method. The surface shall be dry before application of the Silanes and
Siloxanes.
24.8.4 Mixing of the Chemicals:

The Silanes and Siloxanes of approved brand and manufacture shall be applied by diluting with
mineral Turpentine oil in the ratio of 1:12 i.e. one part of the approved chemical and 12 parts of
mineral turpentine oil. The chemicals shall be properly mixed before application in a clean container.
24.8.5 Surface Application

When the stone masonry is dry the chemicals are sprayed in uniform and even layers to the
required number of coats as decided by the Engineer in Charge. Each coat shall be allowed to dry
for 3-4 hours before application of the next coat.

Spraying should be done only when dry condition prevails. During spraying the spray gun shall
be held perpendicular to the surface to be coated and shall be passed over the stone masonry in a
uniform sweeping motion. Different air pressures and fan adjustment shall be tried so as to obtain
the best application. The Air pressure shall not be kept too high as otherwise the chemical will fog up
and will be wasted.
At the end of the job, the spray gun shall be cleaned thoroughly so as to be free from dirt or
chemical. Incorrect adjustments shall be set right, as otherwise they will result in variable spray
patterns, runs, sags and uneven coats.
24.8.6 Measurements
Measurements shall be same as described in para 24.1.6
24.8.7 Rates
described above. Scaffolding if required and provided shall be paid for separately.

SUB
SUB HEAD
HEAD :: 25.0
22.0
STRUCTURAL GLAZING
WATER PROOFING ALUMINIUM
TREATMENT
COMPOSITE PANEL
1257
CONTENTS
25.1 Materials (General) 1261
25.2 Sealants & gaskets 1262
25.3 Glass 1264
25.4 Metal coatings 1265
25.5 Standards 1266
25.6 Design 1266
25.7 Shop drawings 1266
25.8 Documentation and certification 1267
25.9 Samples and mock-up at site 1268
25.10 Storage, protection and programme 1268
25.11 Performance requirements 1269
25.12 Curtain glazing and aluminium composite panel 1270

cladding systems
25.13 Measurements 1272
25.14 Rate 1272
SUB HEAD 25.0 : STRUCTURAL GLAZING ALUMINIUM COMPOSITE PANEL

1259
25.0 STRUCTURAL GLAZING ALUMINIUM COMPOSITE PANEL
25.1 Materials (General)

25.1.1 Materials and components used shall be of the first / superior quality and suitable for the
purpose.
25.1.2 All materials shall be free from any defects that may impair the strength, functioning/ performance
or appearance of the curtain wall or adjacent construction.
25.1.3 Fasteners
25.1.3.1 The type, size, alloy, quantity and spacing of all anchor fasteners and/or anchorage devices
shall be as required for the specified performance standards.
25.1.3.2 Bolts, anchors and other fastening devices like screws, nuts, washers etc. shall be of
approved types as required for the strength of the connections, shall be self-locking, unless otherwise
specified. These shall be of austenitic stainless steel of specified grade and shall be torque tightened,
wherever required, to achieve the maximum torque tension relationship in the fasteners. Washers,
nuts and all accessory items shall be of the same material as fasteners. The rivets/ nuts, bolts and
washers for fixing insulation layer to the shadow box or with fire-stops (barriers)-cum-smoke seal
shall be stainless steel of approved grade.
Type of fasteners Grade of stainless steel

Anchor fasteners Stainless steel grade 316
Screws, Nuts, Bolts, Washers Stainless steel grade 304
Rivets, toggles and the like Stainless steel grade 304
25.1.3.3 The anchor fasteners shall not be provided using PVC sleeves. Only expandable type self
locking fasteners shall be provided.
25.1.4 Aluminium extrusions

25.1.4.1 In general aluminium alloy for extrusions shall be 6063 T5 or T6 grade as per B.S.1474.
However, the grade and tempering specifications shall be as recommended by the supplier for each
application.
25.1.4.2 All extruded aluminium sections shall be anodized in approved colour to a minimum thickness
of 20 microns or shall be PVDF coil / spray coated in approved colour and shade with metallic
colours to a minimum thickness of 35 microns. The colour and the finish shall be uniform and free of
streaks. The aluminium sections, before coating, shall be suitably cleaned, rinsed, buffed properly
and sealed and protected after anodizing / PVDF coating, till the completion of the work.
25.1.4.3 All surfaces of the aluminium sections designed to receive the sealants shall be finished
properly to match the finish of the parent section as used for initial testing of sealant and aluminium
surface adhesion. Further, it shall be ensured that the entire aluminium surface has adequate sealant
contact and adhesion.
25.1.4.4 Sill sheets, plates and extrusions shall be visually flat under all lighting conditions.
25.1.4.5 The members of aluminium extruded sections for mullions, transoms, members of sub frames
& sash frames shall be in single piece and not be splice jointed in the panel length and height.

1261
25.1.5 Aluminium flashing
25.1.5.1 All flashings shall be made from 1.0 mm thick solid aluminium sheet transparent anodized to
a minimum thickness of 10 microns. It shall be fixed using stainless steel screws dipped in weather
silicone sealant.
25.1.6 Aluminium composite panels

25.1.6.1 The soffits of the canopies / walkways / entrance canopies etc., required as per the architectural
drawings, shall be covered with aluminium composite panel material. The top of the canopies / walkways
/ entrance canopies shall be covered with zincalume sheets. The aluminium composite panel and
zincalume sheets shall be bent to the required profile and fixed as per the approved shop drawings
prepared on the basis of architectural drawings.
25.1.7 Brackets
25.1.7.1 The brackets shall be fixed with high degree of accuracy to achieve the elevation as per the
architectural drawing. The brackets shall have suitable lengths and sections to align curtain glazing
in one face, as required as per the architectural drawings. Nothing extra shall be payable on this
account. The brackets shall be fabricated from M.S rolled sections / plates to have the design strength.
The quality of the weld shall also be ensured as per the standards. These shall be provided corrosion
protection treatment by Hot Dipped Galvanizing. The mass of the zinc coating to be not less than 610
gm. per sqm of steel area to be galvanized. Slots of elliptical or circular shape in the brackets shall be
pre-drilled / machine punched and not flame cut and it shall be done before galvanizing. The surface
of the brackets shall be serrated for additional grip before galvanizing. Washers made of serrated
plates of the corresponding material shall also be provided for additional grip. The directions of the
serration and the slot shall be such that they allow movements as per the design requirement and at
the same time prevent any movement in the other direction. Each bracket shall be fixed to the R.C.C
using anchor fasteners of suitable capacities and in numbers as required as per the design
requirements. The brackets shall be fixed to the structural steel members of the building using stainless
steel bolts & nuts / fasteners of required capacity and in numbers as per the design requirement.
The holes of the required sizes shall be pre- drilled in RCC/ structural steel for fixing anchor fasteners/
bolts etc. Nothing extra shall be payable on this account.
25.1.8 Fittings
25.1.8.1 All hardware and fittings such as patch fittings, handles, locks, stay-arms, floor springs,
friction stays etc. for doors , windows and open able panels shall be heavy duty and of approved
make as specified.
25.1.8.2 Hinges for open able panels shall be heavy duty top hung stainless steel friction hinges
selected for specified wind load and dead loads.
25.1.8.3 All fittings and locks shall be as specified.
25.1.8.4 Each open able panel of the Curtain glazing shall be provided with the fittings as specified
in item nomenclature.
25.2 SEALANTS & GASKETS

25.2.1 Selection of sealants
25.2.1.1 The compatibility and sequence of installation for all sealants must be carefully considered
in all proposals in order to ensure the required curing and performance.
25.2.1.2 Sealants must not degrade and / or fail under any or all design conditions including wind,
thermal and seismic movements, exposure to water and humidity, ultraviolet exposure and / or other
adverse environmental conditions.
CPWD SPECIFICATIONS 2019

1262
25.2.1.3 The designations of sealant types specified herein are intended for general design
guidance only.
25.2.1.4 Final selection for the sealant types shall be based on their conformity with the Performance
Requirements specified herein and as per the recommendations of the sealant manufacturer. It may
use sealant of equivalent grade and characteristics, manufactured by the manufacturer other than
those specified herein, based on recommendations of those sealant manufacturers for specified use
but with the prior approval of the Engineer-in-Charge. The contractor shall submit the documentary
evidence in this regard.
25.2.1.5 All precautions shall be taken during design of structural silicone bite and also during
fabrication of the curtain glazing system to prevent failure of sealant during the guarantee period of
10 years after the date of completion of work and even beyond, upto the expected service life of the
curtain wall.
25.2.1.6 Sealants and gaskets shall not leach, discolour, stain or dry.
25.2.2 Structural silicone sealant

25.2.2.1 The sealant manufacturer shall design the silicone bite for the design loads as specified
and likely to come during the life of the curtain glazing system for arriving at bite size of the structural
silicone sealant.
25.2.2.2 The structural silicone sealant bite as designed by the sealant manufacturer and as per the
approved shop drawings shall be provided.
25.2.2.3 The Structural sealant shall be two part pump-filled Silicone sealant DC 983 of Dow Corning
or equivalent recommended by manufacturer. The weather silicone sealant shall be one-part Silicone
sealant DC 795 of Dow Corning or equivalent of other approved brand as per the list of approved
materials.
25.2.2.4 The structural sealant to be used as specified for all exposed and concealed metal to metal
(including tight or butt type metal to metal assembly prior to assembly) or glass to glass shall be 2-
part silicone sealant, conforming to the manufacturer’s recommendations for the specific uses and
performance criteria. The sealant shall be applied using two-part pump for the same. All the sealing
shall be done in a clean and controlled environment as specified by the silicone sealant manufacturer.
25.2.3 Weather silicone sealant

25.2.3.1 The grade of weather silicone sealants wherever required like for concealed metal to metal,
metal to glass and metal to concrete/ masonry such as embedment and lapping of flashings etc.
where elements are to be installed or embedded, the weather sealant shall be of grade 795 of Dow
Corning or equivalent for the other approved brand, as per the recommendations of the sealant
manufacturers. Also, the gap between the aluminum sections and the glass, if so required, shall be
filled with weather sealant as specified above including providing and fixing backer rod wherever
required as per the approved shop drawings. The weather silicone sealant shall be of approved
colour and shade. The weather silicone sealant for fixing the butt jointed glass for the fixed partitions
shall be transparent in colour DC 791 of Dow Corning or equivalent of other approved brands.
25.2.4 Compatibility
25.2.4.1 All sealants must be non-staining and compatible with adjoining sealants, backup materials,
substrate materials and their respective finishes and/or applied colour coatings. Care shall be taken
to ensure that two different types of sealant should not come in contact with each other unless
compatibility is satisfied as per manufacturer’s specifications.

1263
25.2.5 Caulking compound
25.2.5.1 Dow Corning weather silicone sealant – 795 or equivalent as approved by the Engineer-in-
Charge, ( of approved colour and shade to match adjacent material wherever exposed and visible)
for use around frame/ flashings or between frame/flashing and RCC/ masonry surface.
25.2.6 Gaskets
25.2.6.1 Gaskets and seals shall be of approved quality compatible with substrates, finishes and
other components they are in contact with. All gaskets exposed directly on the exterior face shall be
silicon gaskets, which are UV resistant. They shall not degenerate, discolour or leach on exposure to
solar radiations/ rains/ pollutants etc.
25.2.6.2 Manufacturers’ test Certificate shall be submitted as specified.
25.3 GLASS
25.3.1 General
25.3.1.1 All glass and glazing materials shall be as specified.
25.3.1.2 Vision and spandrel glass shall have characteristics as specified.
The performance characteristics of glass panels, have to be ensured within the constraints of
aesthetic requirements like colour, shade, reflectivity etc. And performance requirements like light
transmission, U value, shading coefficient, relative heat gain etc. as specified. Minor variations in the
characteristics of glass on superior side may be allowed, but without any extra cost to the Department
on this account.
25.3.2 Installation
25.3.2.1 Install glass panels and carry out glazing work as indicated on the drawings and as specified
herein.
25.3.2.2 All glass panels shall be of accurate sizes as required.
25.3.2.3 All glass panels shall have clear undamaged edges and surfaces, which are not disfigured.
25.3.2.4 Any glass panel that does not fit in the curtain glazing system shall be rejected. Therefore,
all care and precautions shall be taken while procuring the glass panels from the manufacturer /
processors of the glass. No claims of any kind or any hindrance shall be entertained from the contractor
on this account.
25.3.2.5 Glass panels shall not be in direct contact with the aluminum framework.
25.3.3 Identification
25.3.3.1 Permanent identification marking on glass shall be accomplished by a technique selected
by the manufacturer. The location of the marking shall be proposed by the Manufacturer and approved
by the Engineer – in - Charge. All glass shall be delivered to site with the manufacturer’s / processor’s
label of identification attached.
25.3.4 Selection of Glass

25.3.4.1 Each type of glass shall be obtained from only one manufacturer and preferably in one lot.

1264
25.3.5 Insulated Glazed Units (IGUs) in the vision panels
25.3.5.1 Insulated glazed units shall be obtained only from approved manufacturers/ processors as
per the approved list.
25.3.5.2 Insulated units shall be factory assembled, with multiple panes, hermetically sealed, separated
by and sealed to spacer tubes perforated on inner exposed face forming airtight dehydrated airspace
inside the insulated units. The IGUs shall be assembled (prepared) by the manufacturer/ processor
of the glass as per the approved list, in their dedicated workshops/ factory.
25.3.6 Laminating units

25.3.6.1 The glasses shall be laminated with interlayer of Polyvinyl butyral (PVB) sheet of specified
thickness
25.3.6.2 The interlayer material (PVB) shall be clear or as specified with no tendency to bubble,
discolour or lose physical and mechanical properties after laminating glasses.
25.3.6.3 The laminated panels shall be free of foreign substances, air or glass pockets and shall not
delaminate at edges.
25.3.7 Precaution in storing and handling glasses

25.3.7.1 The glass manufacturer/ processor shall take necessary precautions as stated below besides
any other precautions not specifically mentioned herein:
25.3.7.1.1 The reflective/ low E coating on the glass shall be protected against scratches, surface
corrosion, staining and/ or any other abrasion.
25.3.7.1.2 The glasses shall not be stored without a clean inter-leaving material. Also they should
not slide against each other.
25.3.7.1.3 The glass shall be protected from weld or grinding splatter.
25.3.7.1.4 The reflective/ low E coating shall be protected against contact with acids or strong alkalies.
The cleaners to be used for cleaning the surface shall be as per the manufacturer’s recommendations.
The glass shall be protected against moisture from humidity, which can stain glass as well as coating.
25.3.7.1.5 Reflective/ low E coating shall also be protected against splashes from paints etc.
25.4 METAL COATINGS

25.4.1 Anodizing / PVDF coating
25.4.1.1 Aluminium extruded sections shall be satin finish colour anodized to minimum 20 microns
thickness, as per the approved colour and shade or PVDF coil / spray coated to approved metallic
colour and shade to minimum 35 microns thickness.
25.4.2 Galvanizing
25.4.2.1 The brackets for the curtain glazing system shall be hot dipped galvanized. The mass of the
zinc coating to be not less than 610 gm. per sqm of steel area to be galvanized.
25.4.3 Samples
25.4.3.1 Three samples shall be prepared, which shall define the colour and gloss of anodizing and
submit them for approval.

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25.4.4 Matching of finish
25.4.4.1 Wherever the same colour finish is specified for extruded aluminium sections and composite
aluminium sheets. It shall be ensured that the colour of both is matched as closely as possible.
25.5 STANDARDS
25.5.1 In general, it shall be followed either of the latest Indian/ International Standards as applicable
for this sub head.
25.6 DESIGN
25.6.1 Architectural drawings and specifications only indicate the required basic dimensions, and
performance criteria.
25.6.2 It shall be ensured that proper structural analysis and design for various load cases and their
combination. This shall include designing and proper sizing of all sections meeting structural and
architectural requirements. The anchor assemblies shall meet the performance and design
requirements including installation of all inserts, fasteners, clips, bracing and framework as required
for the proper anchorage to the structure, unless otherwise specified.
25.6.3 Design of the curtain glazing system shall comply with all Government codes and regulations.
The Contractor shall design the entire curtain glazing system for dead loads, wind loads, seismic
loads, storm, air pollution, thermal stresses, building movements and consequent deflections without
compromising the performance characteristic. Further, the individual members of the structural framing
shall not deflect beyond permissible limits as specified. The design shall comply with the requirements
of the relevant National Building Code and Indian Standard Code/ International Standards, unless
specified otherwise.
25.6.4 The curtain glazing system and its elements shall not sustain permanent deformation or
failure under loading equivalent to 1.5 times the design wind pressure.
25.6.5 The specified deflections must be reduced if they are in any way detrimental to curtain glazing
system and building.
25.6.7 It shall be ensured that the elevations are strictly as per the architectural drawings and that
the intent of the architectural design is retained. Visual appearance shall be a key consideration for
acceptance of work.
25.7 SHOP DRAWINGS

25.7.1 Submittals
25.7.1.1 The contractor shall prepare shop drawings based on approved design and submit the
same to the Engineer –in-charge for approval.
25.7.1.2 The review of the shop drawings shall be limited to their conformity to the architectural and
structural design concept & specifications.
25.7.1.3 No fabrication shall be taken up until the shop drawings and all other related submittals,
documentation, certification, samples and the mock-up for that work have been reviewed and
approved by the Engineer-in-charge.
25.7.2 Scope of shop drawings

25.7.2.1 Shop drawings shall incorporate scaled and dimensioned plans, elevations, sections and
complete size details for all the works.

1266
25.7.2.2 The shop drawings shall indicate the required dimensional profiles and modules, function,
design and performance standards and in general cover all dimensions and details required to
fabricate and install the curtain glazing system.
25.7.2.3 The contractor shall verify and co-ordinate the shop drawings with all applicable and inter-
related trades, drawings and specifications.
25.7.2.4 All dimensions / modules, etc., shall be field checked and the drawings shall be modified, if
required, based on actual measurements at site.
25.7.2.5 Details shall show and specify all metal sections, types of finishes, areas to be sealed and
sealant materials, gaskets, applicable construction materials including fasteners and welds, all
anchorage assemblies and components, fabrication and erection tolerances for the work.
25.7.2.6 All details shall be subject to the approval of the Engineer-in-Charge, after incorporating all
the modifications suggested by the Engineer-in-Charge.
25.7.3 Section profiles

25.7.3.1 Profile adjustments, if required as per the site conditions may be allowed by the Engineer-
in-Charge subject to meeting the architectural / performance requirements. However, this shall be
carried out only with the written approval of the Engineer-in-charge provided that the general design
and intent of the drawings and specifications are also maintained. Also, if any new / non-standard
aluminium extruded section is required as per the site requirement and / or the architectural drawings
for functional and / or aesthetic reasons, the contractor shall procure the same from the approved
manufacturers for the aluminium sections, even if it entails preparing new die, etc. Nothing extra shall
be payable on this account.
25.8 DOCUMENTATION AND CERTIFICATION

25.8.1 The manufacturer’s certificate for compliance of the various components/ materials for the
works (under this sub head) as per the manufacturer’s specifications for the various characteristics.
A copy of the manufacturer’s test report for each lot of material procured and supplied for the work
shall also be obtained from the respective manufacturers and submitted to the Engineer-in-Charge
for the record.
25.8.1.1 Glass and glazing documentation

25.8.1.1.1 Before taking up the work, the glass manufacturer / processor shall submit written
certification for the review of the Engineer-in-Charge and record, stating that all glass (properties as
specified such as U value, shading coefficient, light transmission, solar factor, relative heat gain etc.)
and glazing requirements (including heat strengthening/ toughening, reflective soft coating, low E
coating, lamination, fabrication of IGUs including sealants) as per the shop drawings are recommended
by them for use related to their specific applications and design parameters and that they are in
conformity with the specifications.
25.8.1.1.2 Tests shall be carried out for glass, including properties after processing, for each lot
supplied, by the glass manufacturer / processor in his factory /laboratory or any other accredited
laboratory and the copies of the test results shall be obtained by the contractor and submitted to the
Engineer-in-Charge for the record.
25.8.1.2 Sealant Documentation

25.8.1.2.1 All sealant applications must be clearly designated on shop drawings.

1267
25.8.1.3 Quality control documentation
25.8.1.3.1 The methodology and quality assurance statement shall be submitted for quality control
procedures for the review and approval of the Engineer-in-Charge before taking up the work to
ensure the design integrity and performance of the curtain glazing, aluminium composite panel
cladding and aluminium work (PVDF coated).
25.8.1.3.2 The Engineer-in-Charge or his authorized representatives may visit the plant / workshop
/ factory to inspect material, fabrication and quality assurance procedures.
25.9 SAMPLES AND MOCK-UP AT SITE

25.9.1 Submittals
The samples of the following materials together with detailed technical data / catalogues shall be
submitted for review and approval of the Engineer-in-Charge along with the shop drawings..
25.9.1.1 Aluminium Composite Panel : Each type and thickness 600mmx600mm
25.9.1.2 Aluminium extrusions : Each section: 500mm long.
25.9.1.3 Glass : Each type 600 mm x 600 mm.
25.9.1.4 Gaskets, separators, glass setting blocks / spacer tape, etc : Each section or unit, backer
rods, 300mm long or unit.
25.9.1.5 Bracket, fasteners and Connecting devices : Each type and size.
25.9.1.6 Finish samples : After approval of the final finish coating, the Engineer-in-Charge shall be
provided with three (3) approved samples.
25.9.1.7 Ironmongery and accessories, as applicable.
25.9.1.8 Finished flashing samples
25.9.1.9 Finished samples of shadow boxes, fire stop (barrier)-cum smoke seals
25.9.1.10 Structural and weather silicone sealant
25.9.2. Mock-up at site

Before the fabrication and site installation is taken up and after the approval of shop drawings by the
Engineer-in-Charge, a mock-up shall be prepared of his proposed curtain glazing system for a size of
panel not exceeding 6 sqm. The mock-up shall be essentially put up at site for final approval of all
materials and installation details by the Engineer-in-Charge. The mock up shall not form part of the
work and shall not be paid for. It shall be dismantled and taken away by the contractor at his own cost,
with the prior permission of the Engineer-in-Charge. Nothing extra shall be payable on this account.
25.10 STORAGE, PROTECTION AND PROGRAMME

25.10.1 A schedule of procedure shall be submitted for inspection during installation so as to control
and assure quality on the job site.
25.10.2 A detailed method statement shall be submitted for the protection of the surface of the
curtain glazing, aluminium composite panel cladding and aluminium work (PVDF coated), etc during
delivery and erection, with description as to when the protection can be removed. The protection
paper shall be kept for a period as recommended by Engineer-in-Charge and shall be replaced with
the fresh protection paper, if so required. Further, it shall not have acid content, which in any manner
may affect the substrate.

1268
25.10.3 Delivery and Storage of Materials: All materials delivered to site shall be stored in allocated
spaces where the stored materials shall not get exposed to rainwater, moisture or damage, and shall
permit easy access to and handling of the materials. Materials shall be stored neatly and properly
stacked.
25.10.3.1 Factory made glazing units and/or their components shall be transported, handled and
stored in a manner to preclude damage of any nature.
25.10.3.2 Necessary materials, required for erection at the site shall be delivered in labeled containers
by the manufacturer / supplier.
25.10.3.3 All units or components, which are cracked, bent, chipped, scratched or otherwise defective
and unsuitable for installation shall be removed and replaced by the contractor. Nothing extra shall
be payable on this account.
25.11 PERFORMANCE REQUIREMENTS

All components, assemblies and completed work shall conform to the various performance standards
as applicable in respect of thermal movement of the curtain glazing, allowance for vertical and horizontal
expansion and building movement and related building tolerance etc. The design and installation of
the curtain glazing system shall accommodate all inherent building movements and deflections and
the fabrication and installation tolerances of all related work not involved in this section without the
loss of, or any detrimental effect to, the performance requirements herein specified. The contractor
shall verify and coordinate all such movements and tolerances with the Engineer-in-Charge before
designing the components of the curtain glazing system so that movements and deflections in the
structure do not at any time affect the integrity and safety of curtain glazing system and vice versa.
25.11.1 Thermal property

25.11.1.1 All insulation materials, fire-stops (barriers)-cum-smoke seal shall comply with the current
requirements of the Fire Officer, MIDC and other authorities.
25.11.2 Structural properties

25.11.2.1 The curtain glazing system shall be anchored to the R.C.C floor through serrated Hot Dipped
Galvanized M.S brackets. As far as possible, the contractor shall take all precautions to avoid cutting
through any reinforcement bars while fixing the brackets. The cost includes provision of sleeves/ leave
slots at appropriate locations during casting of the concrete itself for making provision for fixing brackets
for the curtain glazing system and to avoid chipping/ dismantling of concrete. The slot shall be filled up
with concrete of the same grade in a workman like manner, after fixing the brackets. Any defect in
alignment/ plumb in the building face shall be rectified by chipping/ dismantling of the concrete/ masonry
and repairing the same as specified to achieve the required alignment of the curtain wall as specified.
Any change in lengths of bracket/s required on this account and the consequent requirement of their
sections and sizes shall be carried out. Nothing extra shall be payable on this account.
25.11.2.2 No holes shall be burned, filed or drilled in any structural steel/ RCC members unless
expressly approved by the Engineer – in – Charge.
25.11.2.3 Member shapes and/or profiles if schematically shown on the Architectural drawings are
not necessarily the exact shapes required or best suited for the particular conditions. Final shapes
and locations shall be as designed by the contractor and are subject to the review and approval of
the Engineer – in – Charge.
25.11.2.4 All framing members shall be shop fabricated and finished as specified.

1269
25.11.3 Concrete tolerances
25.11.3.1 While fixing the brackets for curtain glazing system, the contractor shall take into account
the variation in the concrete and the masonry faces to which the structural framework of the curtain
glazing system is to be fixed and such variations shall be adjusted in the lengths of brackets to align
them in perfect plumb. The bracket shall be designed accordingly. Nothing extra shall be payable on
this account.
25.11.4 Fire stops (barriers)-cum-smoke seal and interface with building

25.11.4.1 Gaps between the building face and the curtain glazing system at soffit level between the
successive floors shall be closed as specified with fire-stops (barriers)-cum-smoke seal. It shall have
the required fire resistance to be approved by Fire Officer. Suitable gap for accommodating deflections
of the aluminium framing of curtain glazing system as per the approved shop drawings shall be
maintained between the fire-stops (barriers)-cum-smoke seal and the curtain glazing system. This
smoke seal shall however be provided using backer rod and weather silicone sealant as specified
and as approved by the Engineer-in-Charge.
25.11.4.2 The fire-stops (barriers)-cum-smoke seal shall consist of 1 mm thick plain G.I. sheet tray with
100 mm thick layer of non inflammable heat insulating material, rock wool, having density of minimum 64
Kg. per Cum. of the make as approved by the Engineer-in-Charge. The rock wool layer shall be attached
to G.I sheet using stainless steel rivets/ nuts, bolts and washers. The tray shall be fixed to the RCC /
Masonry surface by using stainless steel screws dipped in weather silicone sealant as per the approved
shop drawings. Screws with plastic sleeves shall not be allowed to be used for the above fixing.
25.11.4.3 An aluminium flashing of 1.0 mm thick shall be permitted transparent anodized (10 micron
thickness) solid aluminium sheet of the approved design and profile at the window sill level and also
fill the gap between the aluminum flashing and the curtain glazing using weather silicone sealant as
specified and as approved by the Engineer-in-Charge. Also, the fasteners/ screws to be used for
fixing flashing shall be dipped in weather silicone sealant before using.
25.11.5 Acoustics
25.11.5.1 Gaps between the mullions and the partitions of the cabins shall be suitably closed by
double skin partition as directed by the Engineer-in-Charge including allowing for permissible
deflections of mullions as per design requirements but without affecting the partitions and the curtain
glazing system. The payment for this partition work shall be made under relevant item.
25.11.5.2 Provisions shall also be made to prevent metal to metal rubbing, any rattling, noise due to
thermal changes and wind pressure by using Teflon separators and shims.
25.11.6 Visual appearance

25.11.6.1 It shall be ensured that the elevations are strictly as per the Architectural drawings and
that the intent of the architectural design is retained. Visual appearance shall be a key consideration
for acceptance of work.
25.12 CURTAIN GLAZING AND ALUMINIUM COMPOSITE PANEL CLADDING SYSTEMS

25.12.1 General
25.12.1.1 Movement of building components to which the curtain glazing system is attached including
long term and short term movements due to thermal effect, structural effect, wind pressure, seismic
forces, erection or dead loads, creep, column shortening, deflection, torsion and vibrations etc shall
be free and noiseless. This shall be achieved without any strain or stress being transferred to the
glass, without buckling of any components, without excessive stress to any members or assemblies
and without compromising on any of the performance requirement of the curtain wall.

1270
25.12.2 Waterproofing
25.12.2.1 Following precautions shall be taken by the contractor to ensure that the curtain glazing
system is completely water tight during its guarantee period as well as expected service life besides
any other precautions not specifically mentioned herein:
25.12.2.1.1 A drainage system must be incorporated into the curtain glazing system. The curtain
glazing system shall have provision for air pressure equalization (all the internal spaces shall be
vented by acceptable means to ensure air pressure equalization ) so that water leakage and
condensation, if any shall be drained or discharged to exterior face of the curtain glazing.
25.12.2.1.2 Care should be taken that the sections of the aluminum extrusions used for structural
framing of curtain glazing provide for proper drainage of water that in-filters into the system by
gravity and for this the section should have proper slope and weep holes as required. These shall be
clearly indicated on the shop drawings.
25.12.2.1.3 Movement of water on exposed faces must be controlled to ensure that water is not
retained and that elements will not be damaged or corroded by water and to minimize the potential
for algae and fungal growth as a result of standing or trapped water.
25.12.2.1.4 EPDM gaskets of the quality as specified and of required size and thickness shall be
provided at all required locations to prevent ingress of water or moisture. The same shall be indicated
on the shop drawings also.
25.12.2.1.5 EPDM gaskets of the quality as specified and of required size and thickness shall be
provided at all required locations to prevent ingress of water or moisture. The same shall be indicated
on the shop drawings also.
25.12.2.1.6 Aluminium sheet flashing using 1.0mm thick transparent anodized (10 microns) aluminium
sheet wherever required shall be provided including sealing the gap between the flashing and the
other material like RCC, masonry, aluminium etc. by using weather silicone sealant as specified.
25.12.3 Mullions and transoms

25.12.3.1 The sections of mullions and transoms shall be designed to restrict deflection under dead
loads, wind load, seismic loads etc. as specified and shall be rigid and stable enough to support and
retain the in-fill panels in position under all conditions. The mullions and transoms shall also be
designed for additional horizontal loads from the cleaning equipment and process besides horizontal
live loads as specified.
25.12.4 Spandrel units

25.12.4.1 Spandrel shall be of glass having same colour matching with vision areas after using a
shadow box as specified.
25.12.4.2 Structural spandrel wall, fins, slab or beam, aluminium frame work, anchor fasteners,
brackets, shadow boxes, fire stop(barrier)-cum-smoke seals and other construction shall not be
visible through the glass in the spandrel portion of the curtain glazing from the exterior and shall be
fully concealed behind the shadow box.
25.12.4.3 A shadow box shall be provided at a distance of minimum 50 mm behind the spandrel
glass panel to ensure that the insulation panel material does not come in contact with the soft coating
of the spandrel glass to prevent any damage to the coating on account of any chemical reaction or
otherwise. It shall consist of an approved black fibre glass non-woven tissue stuck on surface #1of

1271
50 mm thick semi-rigid fibre glass wool insulation panel of minimum density of 48 kg per cum., and
1.5 mm thick transparent anodized (10 microns) solid aluminium sheet tray, on surface #2 by using
suitable stainless steel rivets/ nuts, bolts and washers to hold the insulation panel in position. The
periphery shall be properly sealed. Surface #1 shall be adequately protected against damage until
spandrel glazing is done. Further, care shall be taken that the aluminium sheet backing of the shadow
box does not heave or warp due to thermal stresses and/or its self-weight. Proper gaps at the edges
of the tray shall be provided to accommodate movements on account of thermal stresses besides
making elliptical slots if required to facilitate movements. The shadow box shall be fixed to the structural
framing of the curtain glazing by using stainless steel screws. The fixing arrangement shall be as per
the approved shop drawings.
25.12.5 Ventilators, open able windows and doors

25.12.5.1 Ventilators, openable windows and doors shall be provided at positions as shown on the
architectural drawings. The openable panels when in closed position shall remain watertight under
all weather conditions and pass the water tightness tests as specified. Besides, the openable panels
shall appear similar to the fixed ones from outside.
25.12.5.2 All hardware and accessories shall be provided and fixed by the contractor and shall be as
specified.
25.12.6 Coping and soffit trimmer

25.12.6.1 All coping and soffit panels shall have aluminium structural frame fixed rigidly to the
structure.
25.12.6.2 Effective drainage system shall be provided to drain out the water that may penetrate
through the joints, on to the exterior face of the curtain glazing.
25.12.6.3 Coping and soffits shall be visibly flat in all lighting conditions.
25.13 MEASUREMENTS
All the aluminium sections including snap beadings fixed in place shall be measured in running
meter along the outer periphery of composite section correct to a millimeter. The weight calculated
on the basis of actual average (average of five samples) weight of composite section in kilogram
correct to the second place of decimal shall be taken for payment (weight shall be taken after
anodizing). The weight of cleat shall be added for payment. Neither any deduction nor anything extra
shall be paid for skew cuts
The height and width of double glazed/single glazed unit (the area of glass unit outside the snap
beading shall only be measured) as fixed in place shall be measured correct to one centimeter and
area calculated in sqm. correct to second place of decimal shall be taken for payment.
25.14. RATE
25.14.1. Rate shall includes cost of all inputs of labour, materials including wastages, T &P, equipments,
other enabling temporary structures and services and all other incidental charges, if any, not
specifically mentioned here, but as required for complete design, proof checking, engineering,
fabrication, assembling, delivery, anchorage, installation, protection of curtain glazing, aluminium
composite panel cladding and aluminium work (PVDF coated), etc. and making the system water
tight (wherever specified), all complete, all in accordance with the true intent and meaning of the
specifications and the drawings taken together, regardless of whether the same may or may not be
particularly shown on the drawings and / or described in the specifications , provided that the same
can be reasonably inferred there from. The curtain glazing, aluminium composite panel cladding and

1272
aluminium work (PVDF coated) shall have framing which shall be structurally and mechanically
designed to achieve the architectural elevations as well as performance parameters specified herein.
Anchorage shall include all supporting brackets & anchor fasteners, as required to rigidly secure the
structural framing to the RCC / Masonry / structural steel members of the building.
25.14.2. The curtain glazing, aluminium composite panel cladding and aluminium work (PVDF coated),
etc. work shall include but will not necessarily be limited to the following:
25.14.2.1 Frames, fixed glazed / vision panels, spandrels, hard wares, open able panels, as in the
drawings inclusive of all accessories and fittings. Glass wool Insulation panel (shadow box), fire stop(
barrier) - cum - smoke seals, splice plates, connectors, sleeves, anti-buckling clips etc.
25.14.2.2 Anodized aluminium work for framing of curtain glazing as well as other aluminium work
PVDF coated) for trellis, louvers, fins, box sections, capping, strip etc wherever indicated in the
schedule of quantities and drawings. Glazes doors.
25.14.2.3 Structural, weather and other silicone sealants within and all round the perimeter of all the
work under this sub head for fabricating IGUs, holding the glass to the aluminium & glass to glass
and to provide water tightness to the curtain glazing.
25.14.2.4 EPDM / silicone gaskets, trims, shims, setting blocks, double sided spacer tape, spacer
blocks, weathering strips etc.
25.14.2.5 All sealing and flashings including sealing at junctions with the building members.
25.14.2.6 All brackets, anchor fasteners, screws, inserts, nuts, bolts & washers, and attachments
required for complete installation and fixing to the RCC, masonry and/or the structural steel members
of the building.
25.14.2.7 All accessories, fasteners, screws, nuts and bolts, toggles, rivets etc. and other items
implied in the drawings and the specifications though are not specifically indicated.
25.14.2.8 Isolation of all dissimilar metal surfaces as well as moving surfaces by use of TEFLON
(PTFE) separators.
25.14.2.9 Engineering proposals, design, drawings and Architectural data.
25.14.2.10 Shop drawings, engineering data and structural calculations (analysis & design) of all
systems including aluminium structural framing, fasteners, sealants etc.
25.14.2.11 Scheduling and monitoring of the work.
25.14.2.12 Cost of all samples of the individual components, mock-ups at site and field tests.
25.14.2.13 Coordination with work of other agencies.
25.14.2.14 Protection during storage and construction until handing over the building for
occupation etc.
25.14.2.15 All final exterior and interior cleaning of the curtain glazing, aluminium composite panel
cladding and aluminium work (PVDF coated) etc. Before handing over the building for occupation.

1273
25.14.2.16 Hoisting, staging, scaffolding and temporary enabling structural work/services, cranes
and cradles etc.
25.14.2.17 Specified tests, inclusive of necessary records, reports, logbook etc.
25.14.2.18 Design and performance guarantee in the enclosed format.
25.14.2.19 Construction monitoring for regular quality control and technical inspection to ensure
the work conforms to the approved shop drawings and details (including any modifications made
after field testing) and acceptable standards of quality including monitoring the progress of the work.

1274
SUB
SUB HEAD
HEAD :: 26.0
22.0
NEW TECHNOLOGIES
WATER & MATERIALS
PROOFING TREATMENT
1275
CONTENTS
26.1 Phenol Bonded Bamboowood Flooring 1282
26.2 Phenol Bonded Bamboo Wood In Wall Skirting 1284
26.3 Phenol Bonded Bamboowood Wall Cladding 1285
26.4 Phenol Bonded Bamboowood Panelled Or Panelled 1286

And Glazed Shutters For Doors Windows,
Clerestorey Windows
26.5 Phenol Bonded Bamboo Wood Paneling 1287
26.6 Factory Made Door Frame Of Phenol Bonded 1289

Bamboowood
26.7 Bamboo Mat Corrugated Sheet (BMCS) 1290
26.8 Phenol Bonded Bamboo Mat Board For False 1292

Ceiling
26.9 Bamboo Mat Board For Partition To Frame 1292
26.10 Wall Panelling With Phenol Bonded Bamboo 1293

Mat Board
26.11 Extruded Polystyrene Rigid Insulation Board 1296
26.12 Under Deck Insulation System 1297
26.13 Factory Made Solid Foam Upvc Profile For Kitchen 1298
Cabinet Frame And Shutter/Partition
26.14 Reinforced Soil Retaining Walls Using Geogrids 1302
26.15 Aluminum Profile Industrial Troughed Sheet Roofing 1311
26.16 Calcium Silicate False Ceiling (Tegular Edged) 1313
26.17 Calcium Silicate False Ceiling (Micro-Edged) 1315
26.18 Calcium Silicate Wall Paneling (Fully Perforated 1317

Square/ Butt Edged)
1277 SUB HEAD 26.0 : NEW TECHNOLOGIES & MATERIALS

26.19 Calcium Silicate False Ceiling (Tegular Edged- 1319
Fixed To Existing T-Frame)
26.20 Glass Fibre Reinforced Gypsum (GRG) False 1321

Ceiling (Semi Perforated Micro Tegular Edged)
26.21 Glass Fibre Reinforced Gypsum (GRG) False 1323

Ceiling (Fully Perforated Micro Tegular Edged)
26.22 Mineral Fibre False Ceiling (Beveled Tegular 1324

Mineral Fibres)
26.23 Mineral Fibre False Ceiling (Beveled Tegular 1326

Mineral Fibre Anti-Microbial)
26.24 Chipping Of Unsound / Weak Concrete: 1326
26.25 Cleaning Of Existing Reinforcement And Passivating 1326

Its Surface
26.26 Drilling Suitable Holes In RCC Or Plain Cement 1327

Concrete
26.27 Bonding Coat: 1327
26.28 Providing, Mixing And Applying SBR Polymer 1328

Modified Cement Mortar
26.29 Applying SBR Polymer Modified Cement Concrete 1328

For Structural Members
26.30 Providing And Injecting Grout 1329
26.31 Protective Fabric Screens 1330
26.32 Cleaning Of Exposed Concrete Surface By Sand 1330

Blasting
26.33 Shotcreting 1331
26.34 Providing And Inserting Galvanized Steel Injection 1331

Nipple
26.35 Providing & Fixing Hard Drawn Steel Wire Fabric 1332
26.36 Light Gauge Steel Framed Structure (LGSFS) 1332
26.37 External Wall System On Light Gauge Steel Frame 1333

Work With Outer Face Having 6mm Thick Fiber
Cement Board

26.38 Internal Wall Panels On Light Gauge Steel Frame 1335
Work With 12.5mm Thick Gypsum Plaster Board
26.39 Exterior Face Panels Breathable Vapour Barrier 1336

Underneath The Cement Fiber Board
26.40 Moisture Resistant/Fire Resistant 6 mm Thick 1337

Fiber Cement Board
26.41 Glass Fibre Reinforced Gypsum (GFRG) Panel 1337
26.42 Galvanized Steel Deck Sheet Roofing Covered 1343

With Concrete
26.43 Precast Concrete Solid Block 1344
26.44 Precast Technology 1351
26.45 Scaffolding Net 1358
Fig. 26.1, 26.2 Bamboo Mat Corrugated Sheet (BMCS) 1359

& 26.3
Fig. 26.4, 26.5 Bamboo Mat Corrugated Sheet (BMCS) 1360

& 26.6
Fig. 26.7 Bamboo Mat Corrugated Sheet (BMCS) 1361
Fig. 26.8 Cavity Wall Thermal Insulation System With 1361

Rigid Foam Insulation
Fig. 26.9 Under Deck Insulation System 1362
Fig. 26.10 Geogrids 1363

26.11 & 26.12
Fig. 26.13 A Aluminum Profile Industrial Troughed Sheet - 1363

& 26.13 B Self- Drilling Fasteners
Fig. 26.14 Galvanized Steel Deck Sheet 1364
Fig. 26.15 Shear Connectors 1365
Fig. 26.16 Ecofriendly Light Weight Calcium Silicate False 1366

ceiling (Micro Look Edge)
Fig. 26.17 Ecofriendly Light Weight Calcium Silicate Wall 1367

Panelling (fully Perforated Square/ Butt Edged)


1 IS 277-1992 Galvanized Steel Sheets (Plain And Corrugated)-Specification
2 IS 737 Wrought aluminium and aluminium alloy sheet and strip for
general engineering purposes-Specification
3 IS : 801-1975 Code of Practice for Use of Cold Formed Light Gauge Steel
Structural Members In General Building Construction
4 IS : 875-1987 Design Loads
5 IS 1254 Corrugated aluminium sheet
6 IS 1343 Prestressed Concrete - Code Of Practice
7 IS 2095:2011 Gypsum Plaster Boards - Specification
8 IS 2676 Dimension for wrought aluminium and aluminium alloy sheet
and strip
9 IS 4671: 1984 Specification For Expanded Polystyrene For Thermal
Insulation Purposes
10 ISO 4898:2008 Rigid cellular plastics -- Thermal insulation products for
buildings -- Specifications
11 IS 4990: 2011 Plywood For Concrete Shuttering Works - Specification
12 IS 5688-1982 Method Of Test For Preformed Block-Type and Pipe-Covering
Type Thermal Insulation
13 IS 8225:1987 Measurement Of Sound Absorption In A Reverberation Room
14 IS 10297-1982 Code of practice for design and construction of floors and
roofs using precast reinforced prestressed concrete ribbed
or cored slab units
15 IS 11447:1985 Code of practice for construction with large panel
prefabricates
16 IS : 13958-1994 Bamboo mat board for general purposes -Specification
17 IS 14862:2000 Fibre Cement Flat Sheets - Specification
18 IS 14862: 2000 Fibre Cement Flat Sheets - Specification
19 IS 14867-1999 Falsework For Concrete Structures - Guidelines
20 IS : 15476-2004 Bamboo Mat Corrugated Sheets - Specification
21 IS 15916 Building Design and Erection Using Prefabricated Concrete-
Code of Practice

26.0 NEW TECHNOLOGIES & MATERIALS
26.1 PHENOL BONDED BAMBOOWOOD FLOORING
26.1.1 MATERIAL
26.1.1.1 Frame: The base frame shall be of strong, dry concrete or as specified like plywood or
wooden of treated and seasoned and frame shall be leveled and smooth. The Bamboowood flooring
tiles shall be fixed with tongue and groove interlocking system, with underlayment of 4mm thick
expanded poly ethylene foam sheets having density 40kg/cum, over prepared surface.
26.1.1.2 Flooring Tiles:

The Bamboowood flooring shall be of 14mm thick with tongue and groove inter locking system of
micro beveled edges, eco-friendly bamboowood tiles high in density and hardness, made from bamboo
grass, a renewable source of raw material.
The Flooring Tiles shall be of size 1800mm length (minimum) and 130mm wide (minimum of
14mm thickness. The Bamboowood planks shall have minimum density of 1000 Kg/m3 & minimum
Hardness 1000 Kgf. The Bamboowood flooring tiles shall have Eco friendly UV coating in approved
colour, texture and factory finished, having Performance Appraisal Certificate (PAC) issued by Building
Materials & Technology Promotion Council (BMTPC). The flooring tiles shall have necessary quarter
round planks of size 1900mm x 18mm and door reducer of size 1900mm x 44mm, wherever required.
The Bamboowood flooring tiles characterized with density, hardness, modulus of rupture, modulus
of elasticity, thermal conductivity as per IS: 3346-1980 < 0.50 W/ m-K, termite resistant as per 6months
termite mound test and borer resistant as per box test, scratch resistance as per Hamburger test of
> 20 N, abrasion resistance as per DIN EN 438-2 of > 100cycle & ASTM D 4060 of >6000 cycle & ISO
15184 of > 1H, impact resistance as per DIN EN 438 P2–12 of > 2 Newton, Indentation Resistant DIN
EN 438 P –14 of > 1 Newton, Chemical Resistance DIN 68861 Part 1 of 5, In flammability DIN 4102
Part 14 of B1, Heat Resistance DIN 68861 Part 6 of 6A.
26.1.1.3 Base Material:

Expanded polyethylene foam sheets of 4mm thickness and having density 40kg/m3.
26.1.2 Fixing of base work and tiles:

The expanded poly ethylene foam sheets of 4mm thickness and having density 40kg/m3 of
available width and running length as underlayment. Place the foam sheet and seal joints with min.
50 mm width masking tape so that it should not overlap. This foam will take undulation and act as
cushion for flooring tiles. Open the boxes of tiles and keep tiles in room for normalizing for 72hrs prior
to installation. First check the dimensions with meter tape to calculate the expansion gap to be left for
sides. For standard room 12ft x 12ft, the expansion gap shall be 15mm and above to this add 0.5mm
for each layer; for width above 25ft gap shall be 30mm. Ends shall have standard 15mm expansion
gap all times. Make a right angle along the longer side of area where flooring to be laid by placing
marking line and use guide strips as specified above. Then start laying down flooring tiles one after
another end to end. Place them against the guide strips along with right angle marking line. Take D-
3 category water resistant glue and apply above tongue with a conical shape glue applicator for
even layer. And place second line of tiles and push in with first layer from sides and match end to end
of this layer. If last tile is longer; then trim the excess and take that to first piece in next layer. Repeat
same again and again till complete laying of flooring in whole area. Keep cleaning the excess glue
coming up on tile surface with moist cloth. Use Silicon based joint sealant of approved quality for the
joints of the tiles. Place door reduce at entrance in last.

26.1.3 Precautions:-
(a) Base concrete must be strong, levelled and dried prior to flooring tiles installation work.
(b) Bamboowood flooring tiles are ready to use as factory finished hence should be the last job
to be carried out in new or under renovation area.
(c) All wet trades such as plastering, conducting, and painting, walling, Ceiling, Air Conditioning
duct work, Electrical chasing or drawing lines & cables, etc should be completed prior to
start the flooring works.
(d) No unauthorized work shall be carried out after flooring is laid.
26.1.4 Maintenance Guidelines

Bamboowood flooring shall be maintained by hardwood floor cleaners as recommended to ensure
that floor stays looking good. It shall be ensured that hardwood floor cleaners are water based,
nontoxic cleaners which have been designed for finished hardwood floors. Cleaner shall be used as
per manufacturer’s instructions.
Types of Drying Methods for the Floors are as follows:
Dry mop: Dirt and grit shall always be removed prior to cleaning Bamboowood floors with an electrostatic
dust control mop/ soft mop/ vacuum cleaner. Bristle broom shall be avoided.
Dry spray: The area of floor or the cleaning pad shall be mist with the hardwood floor cleaner.
Wipe: The floor shall be cleaned with a microfiber cloth or mop using a back and forth motion until it
is dry. Soiled mop or cloth shall be replaced once it becomes soiled to avoid streaking.
Do’s and Don’ts: Do’s

(i) The floor shall be cleaned regularly. Recommendations for cleaning the floor as a guide
shall be as follows:
Low frequented area (residential) – about every 2-4 weeks
Medium frequented area (offices) – about every 1-2 weeks
High frequented area (public places) – about every 1-2 days
(ii) Spills shall be removed promptly
(iii) Mats at exterior and interior doors shall be placed to trap sand 13 and grit from
incoming traffic
(iv) Heavy furniture or appliances shall always be picked rather than sliding them across the floor
(v) Any minor scratches or damage shall be repaired using hardwood flooring cleaners
Don’ts
(i) Do not steam mop or wet mop floor surface area after installation. Excess water can cause
swelling
(ii) Do not let sand, dirt or grit build up. They act like sandpaper and actually abrade and dull
the floor finish
26.1.5 Measurements: Length & breadth of the finished flooring shall be measured correct to a
centimeter from wall to wall. The area shall be calculated in square meter correct to two decimal
places. Expansion joint area shall not be deducted. No deduction will be made of openings of area
upto 0.40 sqm nor shall extra payment be made either for any extra material or labour involved in
forming such openings. For opening exceeding 0.40sqm in area , deduction in measurements shall
be made but extra will be payable for any extra material or labour involved in making such opening.

26.1.6 Rates: The rate shall include cost of all the materials and labour involved in all the operation
described above, including.
26.2 PHENOL BONDED BAMBOO WOOD IN WALL SKIRTING

26.2.1 MATERIAL
26.2.1.1 Frame: The base frame shall be of strong, dry concrete or as specified like plywood or
wood treated and seasoned, frame leveled and smooth. The Bamboowood Wall Skirting tiles shall be
fixed with SS screws including rawl plug, with underlayment of 4mm thick expanded poly ethylene
foam sheets having density 40kg/cum, over prepared surface.
26.2.1.2 Wall Skirting Tiles:

The Bamboowood Wall Skirting shall be of 14mm thick with one side quarter rounded of micro
beveled edges, eco-friendly bamboowood high in density and hardness, made from bamboo grass,
a renewable source of raw material.
The Wall Skirting Tiles shall be of size 1900mm length (minimum) and 85mm wide (minimum of
Hardness 1000 Kgf. The Bamboowood Wall Skirting tiles shall have Eco friendly UV coating in approved
colour, texture and factory finish, having Performance Appraisal Certificate (PAC) issued by Building
Materials & Technology Promotion Council (BMTPC).
The Bamboowood wall skirting tiles shall be characterized with density, hardness, modulus of
rupture, modulus of elasticity, thermal conductivity as per IS: 3346-1980 < 0.50 W/ m-K, termite
resistant as per 6months termite mound test and borer resistant as per box test, scratch resistance
as per Hamburger test of > 20 N, abrasion resistance as per DIN EN 438-2 of > 100cycle & ASTM D
4060 of >6000 cycle & ISO 15184 of > 1H, impact resistance as per DIN EN 438 P2–12 of > 2 Newton,
Indentation Resistant DIN EN 438 P –14 of > 1 Newton, Chemical Resistance DIN 68861 Part 1 of 5,
Inflammability DIN 4102 Part 14 of B1, Heat Resistance DIN 68861 Part 6 of 6A.

Expanded poly ethylene foam sheets of 4mm thickness and having density 40kg/m3 of available
with and running length.

Place the foam sheet and seal joints with masking tape so that it should not overlap. This foam will
take undulation and act as cushion for skirting tiles. Open the boxes of tiles and keep tiles in room for
normalizing for 72hrs prior to installation. Place the wall skirting 2mm above the bamboowood tiles flooring
surface. Use drill machine to make suitable holes in tiles at both ends and accordingly make holes for rawl
plug in wall. Place the rawl plug and then foam and over that place wall skirting tiles and held in place by
50mm SS screws at both ends. Repeat same for entire area. Wall Skirting used to cover the small area
expansion gaps. For larger area expansion gaps need quarter round as shoe to cover the expansion gap
on all sides. Use Silicon based joint sealant of approved quality for the joints of the tiles.
(a) Base concrete must be strong, leveled and dried prior to flooring tiles installation work.
(b) Bamboowood wall skirting tiles are ready to use as factory finished hence should be the
last job to be carried out in new or under renovation area.
(c) All wet trades such as plastering, conduting, and painting, walling, Ceiling, Air Conditioning
duct work, Electrical chasing or drawing lines & cables, flooring, wall cladding etc should be
completed prior to start of skirting works.
(d) No unauthorized work shall be carried out after flooring laid.

Length &breadth of the finished Wall Skirting shall be measured correct to a centimeter. The
length & breadth shall be calculated in running meter correct to two decimal places. All sides length
& breadth where wall skirting is installed shall be measured. No deduction will be made for openings
of areas upto 0.40 sqm nor shall extra payment be made either for any extra material or labour
involved in forming such openings. For opening exceeding 0.40sqm in area , deduction in
measurements shall be made but extra will be payable for any extra material or labour involved in
making such opening.
described above.
26.3 PHENOL BONDED BAMBOOWOOD WALL CLADDING

26.3.1 MATERIAL
26.3.1.1 Frame: The frame shall be made of second class teak wood of treated and seasoned of
size 20x15mm in centre of each tile and bottom and top of work height, 40x15mm placed at ends of
each tile. The frame shall be fixed to wall with 50mm SS screws and raw plug. The Bamboowood wall
cladding shall be laid over back layment of 1.00mm thick expanded poly ethylene foam of density
40kg/cum in two layers first layer on wall surface before fixing wooden frame and second layer on
frame under cladding.
26.3.1.2 Wall Cladding Tiles:

The Bamboowood Wall Cladding tiles shall be of 10mm thick with profiled edges. Eco friendly
bamboowood wall cladding tiles high in density and hardness, made from bamboo grass, a renewable
source of raw material.
The Wall Cladding Tiles shall be of size 1800mm length (minimum) and 130mm wide (minimum) of
Hardness 1000 Kgf. The Bamboowood wall cladding tiles shall have Eco friendly UV coating in approved
colour, texture and factory finish, having Performance Appraisal Certificate (PAC) issued by Building
Materials & Technology Promotion Council (BMTPC). The wall cladding tiles shall have necessary
threshold of size 1900mm x 44mm and T mold of size 1900mm x44mm wherever required.
The Bamboowood wall cladding tiles shall be characterized with density, hardness, modulus of
rupture, modulus of elasticity and thermal conductivity as per IS: 3346-1980 < 0.50 W/ m-K, termite
resistant as per 6months termite mound test and borer resistant as per box test, scratch resistance
as per Hamburger test of > 20 N, abrasion resistance as per DIN EN 438-2 of > 100cycle & ASTM D
4060 of >6000 cycle & ISO 15184 of > 1H, impact resistance as per DIN EN 438 P2–12 of > 2 Newton,
Indentation Resistant DIN EN 438 P –14 of > 1 Newton, Chemical Resistance DIN 68861 Part 1 of 5,
In flammability DIN 4102 Part 14 of B1, Heat Resistance DIN 68861 Part 6 of 6A.

Expanded poly ethylene foam sheets of 1mm thickness and having density 40kg/m3 and second
class teak wood of treated and seasoned.

The expanded poly ethylene foam sheets of 1mm thickness and having density 40kg/m3 of
available width and running length as backlayment. Place the foam sheet and seal joints with
masking tape so that it should not overlap. The frame shall be made of second class teak wood of
treated and seasoned of size 20x15mm in centre of each tile and bottom and top of work height,
40x15mm placed at ends of each tile. The frame shall be fixed to wall with 50mm SS screws and

rawl plug. The frame shall be laid over first layer of foam. Open the boxes of tiles and keep tiles in
room for normalizing for 72hrs prior to installation. Make a right angle along the length and height
of wall by keeping a 10mm gap with all. The Bamboowood wall cladding shall be laid over backlayment
of 1.00mm thick expanded poly ethylene foam of density 40kg/cum on frame under cladding. Use
pneumatic installation gun and tools of pressure 7bar and use BR18G nails. Place wall cladding
tile and hit in head and toe and in centre to pace it. Keep a gap of minimum 3.00mm between two
wall cladding tiles and continue laying as explained above. One can increase gap between tiles as
per their requirement as well. Use T-mold to join two tiles at the ends and threshold in top and
bottom of wall cladding to give a pleasing looks.
(a) Base concrete must be strong, leveled and dried prior to flooring tiles installation work.
(b) Bamboowood wall cladding tiles are ready to use as factory finished hence should be the
last job to be carried out in new or under renovation area.
start of cladding works.
(d) No unauthorized work shall be carried out after wall cladding installation.
Height & breadth of the finished Wall cladding shall be measured correct to a centimeter from wall
to wall. The area shall be calculated in square meter correct to two decimal places. Expansion area
shall not be deducted. No deduction will be made of openings of area upto 0.40 sqm nor shall extra
payment be made either for any extra material or labour involved in forming such openings. For
opening exceeding 0.40sqm in area, deduction in measurements shall be made but extra will be
payable for any extra material or labour involved in making such opening.
described above, including Frame work mentioned in para above including material & hardware
consumed /utilized.
26.4 PHENOL BONDED BAMBOOWOOD PANELLED OR PANELLED AND GLAZED SHUTTERS

FOR DOORS WINDOWS, CLERESTOREY WINDOWS
26.4.1 MATERIAL
26.4.1.1 Frame: The door frame (chowkhat) shall be of wooden of treated and seasoned or
Bamboowood or as specified material. The opening for Shutter of door shall be levelled and smooth.
The Shutter for door shall have profiled interlocking system and be fixed with bamboo pins in position.
The Shutter shall fix to door frame with SS hinges and screws.
26.4.1.2 Shutters of doors:

The Bamboowood Shutters of doors shall be of 30mm thick with pre - molded planks having inter
locking system of micro bevelled edges, eco-friendly bamboowood of high in density and hardness,
made from bamboo grass, a renewable source of raw material.
The Shutters of doors shall be of 30mm thick bamboowood planks. The Bamboowood planks shall
have minimum density of 1000 Kg/m3 & minimum Hardness 1000Kgf. The bamboowood shutters of
doors shall have approved coating in approved colour, texture and factory finished. The bamboowood
shall have Performance Appraisal Certificate (PAC) issued by Building Materials & Technology Promotion
Council (BMTPC). The shutter of doors shall have necessary profile to fit in panelling as required.

The Bamboowood planks pre - molded into shutters of doors characterized with density, hardness,
modulus of rupture, modulus of elasticity, thermal conductivity as per IS: 3346-1980 < 0.50 W/ m-K,
termite resistant as per 6months termite mound test and borer resistant as per box test.

Door frame of wood or metal or Bamboowood or aluminum or others as specified.
26.4.2 Fixing of Shutter of doors:

The pre-molded planks of Bamboowood shutters of doors shall have 10mm wide and 25mm
deep grooves to fit in panels. These planks shall be in vertical and horizontal (middle, top n bottom)
rails. The panels shall fit in rails and all these planks shall fixed together and held in place by bamboo
pins. Doors accessories shall be of adequate metal such as stainless steel butt hinges of size
125x65x1.9mm and minimum 4nos with minimum 4 screws per hand, making 8screws per hinge to be
used. Another fittings like door handle, lock and bolts etc as specified. Normalize doors prior to
installation for 72hrs. First check the dimensions of door frame opening with meter tape and match
same with shutter of door at site; accordingly take installation of shutters of door in frame forward.
There should be a movement gap left between shutter and door frame. Trained carpenter can work
easily on Bamboowood shutters of doors. The carpenter shall use modern hand tools and machines
for better results.
(a) Frame of Door shall be fixed properly with concrete and must be strong, levelled and dried
prior to shutter door installation work.
(b) Bamboowood shutters of doors are ready to use as factory finished hence precautions
should be carried out in new or under renovation area.
installation of doors works.
(d) No unauthorized work shall be carried out after shutter of doors in place at that area.
Length & breadth of the shutters of doors shall be measured correct to a centimeter in fixed
position (overlapping not to be measured in case of double leaved shutters) and the area calculated
in square meter corrected to two place of decimal. No deduction shall be made to form panel openings
or louvers . No extra payments shall be made for shape, joints and labours included in all operation
describe above.
described above, including Frame work mentioned in para above including material & hardware
consumed /utilized.
26.5 PHENOL BONDED BAMBOO WOOD PANELING
26.5.1 MATERIAL
26.5.1.1 Frame: The shutters of doors shall be of Bamboowood planks. The shutter of door shall
have 10mm grooves for panelling to fit in and be leveled and smooth. The panelling for shutters of
doors shall have profiled interlocking system and be fixed with shutters of doors.

26.5.1.2 Panelling for shutters of doors:
The Bamboowood panelling for shutters of doors shall be of 10mm thick with pre - molded planks
having inter locking system of micro beveled edges, eco-friendly bamboowood, high in density and
hardness, made from bamboo grass, a renewable source of raw material.
The panelling for shutters of doors shall be of 10mm thick bamboowood planks. The Bamboowood
panel tiles shall have minimum density of 1000 Kg/m3 & minimum Hardness 1000Kgf. The
bamboowood panel tiles for shutters of doors shall have approved coating in approved colour, texture
and factory finished. The bamboowood panels shall have Performance Appraisal Certificate (PAC)
issued by Building Materials & Technology Promotion Council (BMTPC). The shutter of doors shall
have necessary profile to fit in paneling as required.
The Bamboowood panels pre - molded to fit in shutters of doors characterized with density,
hardness, modulus of rupture, modulus of elasticity, thermal conductivity as per IS: 3346-1980
< 0.50 W/ m-K, termite resistant as per 6months termite mound test and borer resistant as per box
test.

Shutters of door shall be made of Bamboowood to fit in panelling.
26.5.2 Fixing of Panelling for shutter of doors:

The pre-molded panels of Bamboowood shutters of doors shall have 10mm thickness. The shutters
of doors shall have 10mm wide and 25mm deep grove to fit in panelling. The panels shall fit in rails
and all these panels shall be fixed together to smooth level and whole shutter of door with panel
locked in and held in place by bamboo pins. Normalize doors prior to installation for 72hrs. First
check the dimensions of door frame opening with meter tape and match same with shutter of door at
site; accordingly take installation of panelled shutters of door to fix in frame of door. There should be
a movement gap left between shutter and door frame. Trained carpenter can work easily on
Bamboowood panelled shutter doors. The carpenter shall use modern hand tools and machines for
better results.
(a) Frame of Door shall be fixed properly with concrete and must be strong, leveled and dried
prior to shutter door installation work.
(b) Bamboowood panelled shutters of doors are ready to use as factory finished hence
precautions should be carried out in new or under renovation area.
installation of doors works.
(d) No unauthorized work shall be carried out after panelled shutter of doors in place at that
area.
For paneling of shutters of door, length & width of panels shall be measured correct to a centimetre
and the area shall be calculated to the nearest 0.01sqm. The portion of panels insert or glazed panel
inside the grooves or rebates shall be measured for payment.
described above.

26.6 FACTORY MADE DOOR FRAME OF PHENOL BONDED BAMBOOWOOD
26.6.1 MATERIAL
26.6.1.1 Frame: The door frame (chowkhat) opening shall be of strong, or as specified and leveled
and smooth. The Bamboowood frame for doors shall have 10mm gap between concrete and frame.
The frame shall have interlocking system of rails and gap filling foam as back lament, over prepared
surface.
26.6.1.2 Frame for doors:

The Bamboowood frame for doors shall be 65mm thick with pre - molded planks having inter
locking system of micro beveled edges, eco-friendly bamboowood high in density and hardness,
made from bamboo grass, a renewable source of raw material.
The Frames shall be of 65mm thick bamboowood planks. The Bamboowood planks shall have
minimum density of 1000 Kg/m3 & minimum Hardness 1000Kgf. The bamboowood frames shall have
approved coating in approved colour, texture and factory finished. The bamboowood shall have
Performance Appraisal Certificate (PAC) issued by Building Materials & Technology Promotion Council
(BMTPC).
The Bamboowood planks pre - molded into frame for doors characterized with density, hardness,
modulus of rupture, modulus of elasticity, thermal conductivity as per IS: 3346-1980 < 0.50 W/ m-K,
termite resistant as per 6months termite mound test and borer resistant as per box test.

Strong, dry concrete or as specified and smooth and leveled.
26.6.2 Fixing of Frames:

The pre-molded planks of Bamboowood frames shall have interlocking provisions between vertical
and horizontal rails. The frame shall be fixed to strong, dry concrete with jamb. The jamb shall fixed
on both sides of frame with 2nos of 100mm GI screws per jamb and 3nos of jamb each side first and
then insert other end of jamb into concrete hole and locked bamboowood frame in place by concrete.
There shall be a air gap of 10mm all around to bamboowood frame and this gap to be filled with PU
foam and covered with architraves.
(a) Concrete must be strong, leveled and dried prior to installation of bamboowood frame of
door.
(b) Bamboowood frame ready to use as factory finished hence precautions should be carried
out in new or under renovation area.
(c) Jamb should be fixed to sides of frame at equal interval and jamb hole should be made in
advance in concrete prior to installation work.
(d) All wet trades such as plastering, conducting, and painting, walling, Air Conditioning duct
work, Electrical chasing or drawing lines & cables, etc should be completed prior to installation
of frame works.
(e) No unauthorized work shall be carried out after installation of frame at place.
Length & breadth of the frame shall be measured correct to a centimeter as per approved drawings
and prior to installation work. Rails of verticals and horizontal shall be measured with pre-molded
profiles. Inserts of rails shall be measured as thickness of top rail as 65mm. These inserts shall be

taken into account of measurements. The volume shall be calculated in cum correct to four decimal
places. No deduction shall be made inserts. Installation of frame of doors and fitting of accessories
shall be extra payment and be made for labour involved in making such openings.
26.6.5 Rates:
The rate shall include cost of all the materials and labour involved in all the operation described
above.
26.7 BAMBOO MAT CORRUGATED SHEET (BMCS)

26.7.1 MATERIAL
Material and testing criteria as per IS 15476:2004 ( upto amendment No.-4)
26.7.2 Fixing Procedure:-

1. The roof slope should be minimum 20° OR maximum 45°.
2. (a) For 2440mm long BMCS, the purlin spacing should be @ 1145mm centre to centre.
(b) For 2140mm long BMCS, the purlin spacing should be @ 995mm centre to centre.
(c) For 1830mm long BMCS, the purlin spacing should be @ 840mm centre to centre.
(d) In the same Horizontal Plan, the purlin level (Elevation) at all points must be same to
avoid concave / convex formation of BMCS’s surface which will obstruct the proper
flow of water on the BMCS, as shown in the figure no. 26.1
(e) The rafter (1), (2), (3), (4) etc. as shown in figure 26.1, must be perfectly straight
otherwise it will give concave / convex surface of BMCS which will obstruct the proper
flow of water.
3. Minimum 6" (150mm) end lap to be provided while fitting the BMCS on Purlins. See figure
no. 26.2
4. The Standard width of BMCS is 1050mm. There are 9 nos. of Crown and 8 nos. of Valley in
One BMCS of standard width of 1050mm. See figure no.26.3
5. One Corrugation side lap of 110mm to be provided while fitting the BMCS on Purlins. See
figure no. 26.4 below:
6. BMCS & BMRC to be fitted with Self-Drilling Screws with Stainless Steel EPDM bonded
washers compete (See figure no. 26.5) OR 8mm diameter J Hooks / L Hooks, Bolts, nuts,
bitumen washer, galvanized washers complete. (See figure no. 26.6). NAIL should never be
used for fitting the BMCS & BMRC.
7. For fitting the Self-Drilling Screws OR J Hooks / L Hooks, Bolts, nuts etc., the correct size
hole in the BMCS & BMRC must be made with Drill Machine only. The holes should never
be made by PUNCH, as it will crack the BMCS & BMRC.
8. The holes for fixing the Self-Drilling Screws OR J Hooks / L Hooks, Bolts, nuts etc. to be
made on the APEX (Crest) only and NOT in the Valley. See figure no. 26.5 & 26.6.
9. At least one of the fixing Self-Drilling Screws OR J Hooks / L Hooks, Bolts, nuts etc. to pass
through the end lap of BMCS / BMRC. If it is not possible, extra Self-Drilling Screws OR J
Hooks / L Hooks, Bolts, nuts etc. to be provided. The end lap of BMCS / BMRC to be jointed
together. The edges of the BMCS & BMRC should be straight when fixed end to end and
the surface to be plain and parallel to the general plan of the roof. See figure no. 26.7
below:

10. Free overhanging of BMCS to be not more than 300mm.
11. The BMRC Ridge purlin to be fitted at a distance of 200mm from the Apex of the Truss /
Roof.See figure no. 26.7.
12. Polyurethane (PU) Coating Green colour / any other colour coated side must face the SUN
to resist severe Heat & Rain.
13. Polyurethane (PU) Coating Green colour / any other colour of Exterior quality to be applied
after every five years for longer life of the BMCS / BMRC.
BMCS / BMRC cutting should be done with Fine Teeth Carpenter hand saw / electric hand cutting
machine and after cutting, the edges to be sealed with any of the following sealants available in the
markets:
(i) Exterior Grade quality Varnish
(ii) Polyurethane Coating of Exterior Grade quality
(iii) Bituminized Rubber sealant.
(iv) Silicon Based sealant.
The products should be handled with care and the product should not fall on edges during
handling, unloading and loading process.
The BMCS / BMRC procured from must be stored in a covered shed/ location at site with sufficient
cross ventilation inside the covered shed/ location. The BMCS / BMRC must also be stacked on
elevated wooden pallets which are not touching the ground level.
26.7.4 Finish:-
The complete roof shall present a neat and uniform appearance and be leak proof.
26.7.5 Measurements:- ( for DSR’18 item 26.6A)

Length and breadth shall be measured correct to a cm and its area shall be calculated in square
metres correct to two place of decimal.
The superficial area of roof covering shall be measured on the flat without allowance for laps and
corrugations. Portion of roof covering overlapping the ridge etc. shall be included in the measurements
of the roof.
No deduction in measurements shall be made for the opening upto 0.4 sqm and nothing extra
shall be allowed for forming such opening. For any opening exceeding 0.40 sqm in area, deduction
in measurements for the full opening shall be made and in such case the labour involved in making
these openings shall be paid separately. Cutting across corrugation shall be measured on the flat
and not grithed.
26.7.6 Rates:
The rate shall include cost of all the materials and labour involved in all the operation described
except otherwise stated. This includes the cost of roof sheets, L hook, bolts and nuts, bituminous
and galvanized iron washers.
26.7.7 Measurements:- ( for DSR’18 item 26.6B)

The measurement for ridges and hips shall be taken for the finished work along the centre line of
the ridge and hip lines in length , correct to a cm . the laps in adjacent ridges pieces shall not be
measured. The underlay of ridges under expansion joint pieces where the latter are provided shall
however be measured.

26.7.8 Rates:-
The rates shall included the cost of all material and labour specified above , but does not include
(a) the cost of required hook, bolt nuts and screws and their washers, (b) the cost of supplying and
fixing expansion joint pieces, (c) the cost of closing the gaps between plain ridge and the sheet
roofing corrugation. Item(a) above will be covered by the rate of BMCS roofing while item (b) & (c) will
be paid for separately unless specifically included in the description of item of the BMRC.
26.8 PHENOL BONDED BAMBOO MAT BOARD FOR FALSE CEILING

26.8.1 Material
Material and testing criteria as per IS:13958-1994 ( upto amendment No.-4)
26.8.1.1 Frame
The frame work shall consist of GI Tee sections for main runners of size 30x25x0.3 mm thick and
for cross runners of size 25x25x0.3 mm thick and parameter wall angle of GI section of size 25x25x0.4
mm thick fixed to the wall with dash hold fastner 12.5 mm dia and 50 mm long . The frame work shall
be executed in a manner so as to form a grid of 600 mm x 600 mm as specified in the item. The frame
work shall be suspended from ceiling by level adjusting hangers made of 4 mm dia. GI rods fixed to
slab by means of GI ceiling cleats. The ceiling cleats shall be fixed to the slab by means of mechanical
dash fasteners12.5 mm dia and 50 mm long. MS hangers and ceiling cleats shall be painted with a
coat of yellow zinc chromate primer and two coats of synthetic enamel paint.
26.8.1.2 Ceiling Tiles

Ceiling tiles shall be of 4 mm thick phenol bonded Bamboo mat board bound confirm to IS 13958-
1994 of required size.
26.8.2 FIXING OF CEILING TILES

The ceiling tiles shall be placed over the GI frame.
26.8.3 Measurements
Length & breadth of the finished ceiling shall be measured correct to a centimetre. The area
shall be calculated in square metre correct to two decimal places. No deduction shall be made for
making openings for electrical, air conditioning, fire fighting fixtures nor shall extra payment be made
either for extra materials or labour involved in making such openings.
26.8.4 Rate
The rate shall include the cost of all the materials and labour involved in all the operation described
above including frame work, scaffolding etc.
26.9 BAMBOO MAT BOARD FOR PARTITION TO FRAME

26.9.1 MATERIAL
26.9.1.1 Frame
The base frame work to be executed as per items specified and as per direction of Engineer-in-
Charge

(a) Sawing of Bamboo mat board shall be truly straight and square. The Bamboo mat board
shall be planed smooth and accurate to the full dimensions, rebates, roundings, and
mouldings as shown in the drawings made, before assembly. Patchings or plugging of, any
kind shall not be permitted except as provided

(b) Bamboo mat board can be screwed or nailed as per the requirement on the existing frame
work.
(c) The screws used for fixing the mat board shall be sunk into the wood work and their tops
covered with putty.
(d) When the Bamboo mat board is cut, the edges has to be sealed by using any of the
following sealants available in the market.
(e) Bamboo mat board, if used for outside (exterior) a waterproofing coating to be provided on
the board for each longer life against weathering effects.
(f) Cutting should be done with fine teeth carpenter hand saw/ electric hand cutting machine.
(g) The ornament work shall be made if required in true and accurate to the dimensions shown
in the working drawings.
(h) The fixing shall be done true to line and levels.
The Bamboo mat board must be stored in a covered shed/ location with sufficient cross ventilation
inside the covered shed/ location. The Bamboo mat bard must also be stacked on the elevated
wooden pallets which are not touching the ground level. The product should be handled with care
and the product should not fall on edges during handling, unloading and loading process.
Length and breadth shall be measured correct to a cm. Bamboo mat board used for partition
work shall be measured in square metre nearest to two places of decimal. The moulded work shall be
measured in cm running metre i.e. in running metres stating the girth in cm. The sectional periphery
(girth) of moulding excluding the portion in contact with wall shall be measured in cm correct to 5 mm
and length in metre correct to a cm. No deduction will be made of openings of area upto 0.40 sqm nor
shall extra payment be made either for any extra material or labour involved in forming such openings.
For opening exceeding 0.40sqm in area, deduction in measurements shall be made but extra will be
26.9.5 Rates:
The rate includes the cost of materials and labour required for all the operation described above
but excluding the cost of backing or studding.
26.10 WALL PANELLING WITH PHENOL BONDED BAMBOO MAT BOARD

26.10.1 MATERIAL
26.10.2 Grounds
Grounds shall be provided where so specified. These shall consist of first class hard wood plugs
or the class of wood used for fabricating the frames, of trapezoidal shape having base of 50 × 50 mm
and top 35 × 35 mm with depth of 5.0 cm and embedded in the wall with cement mortar 1:3 (1 cement
: 3fine sand) and batten of first class hard wood or as specified of size 50 × 25 mm or as specified,
fixed over the plugs with 50 mm long wood screws. The plugs shall be spaced at 45 to 60 centimeters
centre to centre, depending upon the nature of work. The battens shall be painted with priming coat,
of approved wood primer before fixing.

(a) Sawing of Bamboo mat board shall be truly straight and square. The Bamboo mat board
shall be planed smooth and accurate to the full dimensions, rebates, roundings, and
mouldings as shown in the drawings made, before assembly. Patchings or plugging of, any
kind shall not be permitted except as provided
(b) Bamboo mat board can be screwed or nailed as per the requirement on the existing frame
work.
(c) The screws used for fixing the mat board shall be sunk into the wood work and their tops
covered with putty.
(d) When the Bamboo mat board is cut, the edges has to be sealed by using any of the
following sealants available in the market.
(e) Bamboo mat board, if used for outside (exterior) a waterproofing coating to be provided on
the board for each longer life against weathering effects.
(f) Cutting should be done with fine teeth carpenter hand saw/ electric hand cutting machine.
(g) The ornament work shall be made if required in true and accurate to the dimensions shown
in the working drawings.
(h) The fixing shall be done true to line and levels.
The Bamboo mat board must be stored in a covered shed/ location with sufficient cross ventilation
inside the covered shed/ location. The Bamboo mat bard must also be stacked on the elevated
wooden pallets which are not touching the ground level. The product should be handled with care
and the product should not fall on edges during handling, unloading and loading process.
Length and breadth shall be measured correct to a cm. Bamboo mat board used for paneling
work shall be measured in square metre nearest to two places of decimal. The moulded work shall be
measured in cm running metre i.e. in running metres stating the girth in cm. The sectional periphery
(girth) of moulding excluding the portion in contact with wall shall be measured in cm correct to 5 mm
and length in metre correct to a cm. No deduction will be made of openings of area upto 0.40 sqm nor
shall extra payment be made either for any extra material or labour involved in forming such openings.
For opening exceeding 0.40sqm in area, deduction in measurements shall be made but extra will be
Where only plugs are required to be fixed for the ornamental work, the cost for the same shall be
deemed to be included in the rate of ornamental work and no separate payment shall be made for plugs.
26.10.6 Rates:
The rate includes the cost of materials and labour required for all the operation described above
but excluding the cost of backing or studding.
The testing of bamboowood products and the criteria as listed in Table No.26.1

TESTING CRITERIA OF MATERIAL
Table No. 26.1
Sl no. Characteristic Test Method Criteria
I. Bamboowood ( General Test)
3
1 Density IS: 1708 ( Part 2)1986 ≥ 1000Kg /m
2
2 Modulus of Rupture (MOR) IS: 1708 ( Part 5)1986 ≥ 150 N /mm
2
3 Modulus of Elasticity (MOE) IS: 1708 ( Part 5)1986 ≥ 17500 N /mm
4 Hardness Test IS :1708 ( Part 10), ASTM ≥ 800 kg
D 1037
5 Moisture Content IS: 1708 ( Part-1)1986 ≤12% ( oven dry method)
ASTM D 4442
II. Bamboowood ( Specialized Test)
1 Thermal Conductivity IS: 3346-1980 ≤ 0.50W/m-k
2 Volatile organic compound IS; 13745-1993 ≤8.00mg/100gm (oven dry
method)
3 Termite Test Laboratory Test 6 month in Termite Mound
4 Borer Test Laboratory Test 6 month in Borer Box
5 Flame penetration IS: 1734 (part-3) 1983 ≥30 min
6 Water Absorption IS 2380-1981 ≤ 4% (2 hrs), ≤ 8% (24
hrs)
7 Swelling due to general absorption IS 2380-1981 ≤ 8%
8 Swelling due to surface absorption IS 2380-1981 ≤ 4% (2 hrs), ≤ 8% (24
hrs)
9 Flammability IS: 1731 (Part-3) 1983 ≥ 5 min (time taken for
second ignition)
10 Rate of burning IS 2380-1981 ≥ 10 min (time taken to
lose weight from 70% to
30%)
11 Screw withdrawal Resistance IS: 2380-1981 ≥ 250 Kg (Flat Face)
12 Screw withdrawal Resistance IS: 2380-1981 ≥ 200 Kg (Edge)
III. Flooring/ Wall Cladding Finish (General Test)
1 Gloss Value DIN EN ISO 2813 30 + 5%
2 Scratch Resistance Coin Test Coin Test No Scratch
3 Heat Resistance (Cigarette Test) DIN 68861 Part 6 6A
II. Material : Flooring/ Wall Cladding Finish (Specialized Test)
1 Cross cut test DIN EN ISO 2409 ≤ GT 2
2 Scratch Resistance Coin Test Hamburger planner ≥ 20 Newton
3 Abrasion Resistance DIN EN 438-2 (500g load Initial Point > 100 cycle
per wheel S 33
4 Abrasion Resistance ASTM D 4060 (500g load Initial point > 6000 cycle
per wheel CS 17)
5 Scratch Resistance pencil Hardness ISO 15184 ≥ 1H
6 Scratch Resistance surface Steel wool test, type 2 No scratch
7 Impact Resistance DIN EN 438 part2 – 12 ≥ 2 Newton
8 Resistance to indentation DIN EN 438 part2 – 14 ≥ 1 Newton
9 Chemical Resistance DIN 68861 part 1 5
10 In flammability DIN 4102 part 14 B1
IV. Bamboo Mat Corrugated Sheets( BMCS)

2
1 Density, gm/cm IS :15476:2004 0.75 Min
2 Load bearing capacity. N/mm
a Dry state IS :15476:2004 4.0 Min
b Wet state IS :15476:2004 3.0 Min
3 Impermeability IS :15476:2004 The lower surface shall
not show any formation of
drop of water except for
traces of moisture
4 Water absorption, Percent ( after 24 h IS :15476:2004 15, Max

soaking)
5 Cycle test 1295 IS :15476:2004
SUB No delamination
HEAD 26.0 : NEW TECHNOLOGIES & MATERIALS
or tear.
4 Water absorption, Percent ( after 24 h IS :15476:2004 15, Max
soaking)
5 Cycle test IS :15476:2004 No delamination
6 Resistance to falling weight. The test piece shall not
break or show any crack
or tear.
7 Resistance to fire
a Flame penetration IS :15476:2004 Not less than 10 min
b Rate of burning IS :15476:2004 Not less than 20 min
c Surface spread of flame maximum area of IS :15476:2004 4500
2
char in mm
V. Bamboo Mat Board for general purpose
1 Internal Bond Strength Test
a In Dry State
2
i An average of six test specimen IS:2380( Part 5):1977 0.70 N/mm
2
ii Minimum IS:2380( Part 5):1977 0.50 N/mm
b In Wet State
2
2
c Mycological Test
2
2
2 Surface Strength Test
a In Dry State
2
2
b In Wet State
2
2
c Mycological Test
2
2
26.11 EXTRUDED POLYSTYRENE RIGID INSULATION BOARD

26.11.1 MATERIALS
50mm thick extruded polystyrene rigid insulation board of required size between cavity wall,
complying with ISO 4898:2008 & ASTM C 578-08b-type VI, having thermal conductivity of 0.0289 W/
mk as per ASTM C 578 (Measured as per IS 3346), Compressive strength of > 350 KPA listed as per
ASTM D 1621, density of 34-36 kg/Cum as per ASTM D 1622, Water absorption < 1% by Volume as
per ASTM D 2842, Oxygen Index of 24.1 to 28.1 listed as per ASTM D 2863, cell size 0.4mm of dia (
max) as per ASTM D 3576. Fire retardant property as per DIN 4102 Part 1 of class B2 and as per
ASTM E 84 Class A.
26.11.2 Installation Process

1. The Cavity Wall Insulation system has to be installed by the Trained and authorized Applicator
Only.
2. The insulation board has to be installed from Inside of the wall and should be firmly struck
with the help of water based adhesive applied on all the four sides of the Insulation Board.
3. The Struck insulation board should further be fixed with the help pf PVC fasteners, which
has be fastened on all the four corners in such a way that it should hold adjoining insulation
sheets as well.

26.11.3 Requirement for extruded polystyrene rigid insulation board (See Fig No.26.8)
Since this product of performance based product, the third Party testing is Mandatory and should be
done from any NABL approved laboratory or from any NYLAP approved international laboratory. The
requirements of tests as mentioned in table no.26.2
Table 26.2
Sr. No Requirement Test Standard Remarks
1 Thermal Conductivity Having 180 days aged thermal ASTM C 578 Mandatory
conductivity of 0.0289 W/mk.
2 Compressive strength of > 350 KPA. ASTM D 1621 Mandatory
3 Density of 34-36 kg/Cum. ASTM D 1622 Mandatory
4 Water absorption < 1% by Volume. ASTM D 2842 Mandatory
5 Oxygen Index of 24.1 to 28.1 ASTM D 2863 Mandatory
6 Cell size 0.4mm of dia (max). ASTM D 3576 Mandatory
7 Fire retardant property as per DIN , Part 1 of Class ------ Mandatory
B2
8 Fire retardant property. ASTM E 84 CLASS A Mandatory
Length and breadth of the wall insulation shall be measured correct to a cm and the surface area
worked out in square metre of the finished work.
26.11.5 Rate
above including scaffolding if any required
26.12 UNDER DECK INSULATION SYSTEM

26.12.1 MATERIALS
50mm thick extruded polystyrene rigid insulation board of required size for Underdeck Insulation
System, complying with ISO 4898:2008 & ASTM C 578-08b-type VI, having thermal conductivity of
0.0289 W/mk as per ASTM C 578 (Measured as per IS 3346), Compressive strength of > 350 KPA
listed as per ASTM D 1621, density of 34-36 kg/Cum as per ASTM D 1622, Water absorption < 1% by
Volume as per ASTM D 2842, Oxygen Index of 24.1 to 28.1 listed as per ASTM D 2863, cell size
0.4mm of dia (max) as per ASTM D 3576. Fire retardant property as per DIN , Part 1 of Class B2 and
as per ASTM E 84 Class A.
26.12.2 Installation Process

1. The specified Under Deck Insulation System shall be applied by an Authorized
applicator only.
2. The level of the slab should be checked and kept within permissible limit of variation of
3 to 5mm.
3. The Substrate/Roof Underdeck on which the insulation system needs to be installed must
be free from all waste products such as petroleum, grease, oil, solvents, vegetable or
mineral oil, animal fat etc.
4. The Insulation board must be fixed to the concrete slab from inside with the help of water
based adhesive and Fasteners with PVC Capping. This has to be ensured that the PVC
screws are embedded in the concrete with a minimum distance of 50mm from the edges
and have a pull out strength of 0.3 kN.

26.12.3 Requirement for extruded polystyrene rigid insulation board (Fig.26.9)
Since this product is a performance based product, the third Party testing is Mandatory and
should be done from any NABL approved laboratory or any other accreditation body which operates
in accordance with test ISO/IEC 17011 and accredits labs as per ISO/IEC-17025 for testing. The test
requirements as listed in table 26.3.
Table 26.3
Sr. No Requirement Test Standard Remarks
1 Thermal Conductivity Having 180 days aged thermal ASTM C 578 Mandatory
conductivity of 0.0289 W/mk.
2 Compressive strength of > 350 KPA. ASTM D 1621 Mandatory
3 Density of 34-36 kg/Cum. ASTM D 1622 Mandatory
4 Water absorption < 1% by Volume. ASTM D 2842 Mandatory
5 Oxygen Index of 24.1 to 28.1 ASTM D 2863 Mandatory
6 Cell size 0.4mm of dia (max). ASTM D 3576 Mandatory
7 Fire retardant property as per DIN , Part 1 of Class B2 ------ Mandatory
8 Fire retardant property ASTM E 84 CLASS A Mandatory
Length and breadth of the roofing insulation shall be measured correct to a cm and the surface
area worked out in square metre of the finished work.
No deduction shall be made for openings of areas upto 0.40 square metre. No extra payment will
be made for any extra material or labour involved in forming such openings. For openings exceeding
0.40 square metre in area, deduction for the full opening will be made, but no extra will be paid for
any extra material or labour involved in forming such openings.
26.12.5 Rate
above including scaffolding if any required.
26.13 FACTORY MADE SOLID FOAM UPVC PROFILE FOR KITCHEN CABINET FRAME AND
SHUTTER/PARTITION
26.13.1 Material
uPVC (un-plasticised polyvinyl chloride) is PVC resin blended with acrylic modifier, titanium dioxide
and other chemicals. Then it is processed through machine and mould to produce required solid
Foam uPVC multi-chambered profiles.
The factory made solid Foam uPVC white colour doors and windows shall be comprising of approved
solid Foam uPVC make multi-chambered frames, sash and mullion duly reinforced with appropriate
thickness of galvanised iron section of required length, an appropriate dimension of solid Foam uPVC
glazing beads, EPDM gasket according to frame/sash profile and specified hardware and fittings of
approved make having dimensions as per nomenclature of items. There are two type of solid Foam
uPVC extruded profile series which are used depending upon the size and design of kitchen cabinet
frame. Depth and width of the profile mentioned in the nomenclature of the item is as following.
(i) Depth of a profile (D)- Dimension which is measured at right angles to the glazing plane,
between the front and back face surfaces of a profile.
(ii) Width of a profile (W)-Dimension, measured in the direction of the glazing plane, and
perpendicular to the longitudinal axis of the profile.

Tolerance in profile dimension
For solid Foam uPVC frame, sash and mullion extruded profile minus 5 % tolerance in dimension.
i.e in depth and width of profile shall be accepted. Variation in profile dimension in higher side shall
be accepted but no extra payment on this account shall be made.
26.13.2 Terminology
(a) Frame
Non movable or fixed portion of the kitchen cabinet frame and shutter/Partition attached to
the wall and to which the sash is assembled.
(b) Sash
Movable part in a kitchen cabinet frame and shutter/Partition.
(c) Glazing Bead
Profile which holds the glass or any other partition materials.
(d) Transom (or Mullion)
Profile used within the frame, vertically or horizontally in a frame and/ or sash.
26.13.3 Marking
Solid Foam uPVC profiles shall be legibly and visibly marked in an unobtrusive position not
visible when the window is closed at least once every one meter along the length of the profile and it
should be visible when the window is open as well as shall contain the following minimum information
on the main profile such as frame, sash and mullion/transom.
(i) The name of the trade mark or brand name of the manufacturer
(ii) Date of manufacturing and profile code
26.13.4 Testing (Criteria for conformity)

The Solid Foam uPVC extruded hollow profiles use in kitchen cabinet frame and shutter/
Partition shall conform to the specification as per EN 12608 and other standards as mentioned
in table 26.4
Table 26.4
S.No Name of the test Test Method Specified Parameter
i) Vicat Softening Temperature EN ISO – 306 Shall not be <750C
2
ii) Charpy Impact Strength EN ISO – 179-2 Shall not be <20KJ/m
iii) Flexural Modulus Elasticity EN ISO – 178 Shall not be <2200 N/mm2
iv) Tensile Impact Strength EN ISO – 8256 Shall not be <600 KJ/m2
v) Mean Breaking Stress for welded
corner
a) For the tensile bending test EN – 514 Shall not be <25 N/mm2
or
b) For the compression bending Shall not be<30N/mm2
test
vi) Heat Reversion Test IS:4985-2000 Shall not be> 2.0 %
For the determination of the weld ability of profiles, welded corners shall be tested for tests as
mentioned above. The sample subjected to weld test shall not be finished by grooving and knifing
etc. except for the outside edge of 90 degree angle, which shall be cleaned to permit the sample to
sit fully on to the support.

Minimum percentage of titanium dioxide content in Solid Foam uPVC profiles shall not be less
than 7.00 percent and calcium carbonate content shall not be more than 10.00 percent.
The Solid Foam uPVC kitchen cabinet frame and shutter/Partition shall be factory fabricated by
the approved manufacturer and installation work shall be carried out by them or their authorised
vendor duly approved by the Engineer -in -charge.
26.13.5 Configuration
Indicative size and configuration of kitchen cabinet frame and shutter/Partition to be provided,
same shall be specified in the item and figure included in the tender document.
26.13.6 Fabrication
(i) According to the drawing, the required dimension and length of Solid Foam uPVC frame,
sash and mullion profiles shall be mitred cut and reinforced with galvanised iron section of
required length and thickness.
(ii) All frame and sash profiles of kitchen cabinet frame and shutter/Partition shall be fusion
welded at all corners. Mullion and Transom profiles shall also be fusion welded as per
window / door design so as to prevent any ingress of water or air in the reinforcement
chamber.
(iii) Each corner and joints shall be neatly cleaned by removing all excess material. The weld
shall be finished by grooving, knifing etc. at exposed welded portion only.
(iv) The kitchen cabinet frame and shutter/Partition shall be designed and provided water
drainage/ventilation slots in profile of frame, sash, transom or mullion in order to permit the
escape of entrapped water, moisture from the system. A minimum of 2 nos slots shall be
provided at least at every 500 mm. The drainage shall be so designed as not to puncture
the reinforcement chamber and prevent water running through the reinforcement chamber.
The holes and slots shall offset between the inner and outer walls so as to prevent any
back flow.
(i) The reinforcement material should be non-hygroscopic and should have no adverse effect
of the performance of the kitchen cabinet frame and shutter/Partition and it shall confirm to
any grade of IS 1079 or IS 513.
(ii) Mild steel section reinforcement made from Roll forming process and shall be hot dip zinc
galvanised in accordance with IS 277 with a minimum coating mass of 120 gm/sqm.
(iii) The thickness of reinforcement shall be as such that the Solid Foam uPVC kitchen cabinet
frame and shutter/Partition meet the design wind pressure in accordance with IS 875 (Part-
3) and design of the reinforcement should be as per Solid Foam uPVC profile manufacturer
recommendation and fix to ensure adequate fastener retention.
(iv) Galvanised mild steel reinforcement section is to be inserted in Solid Foam uPVC frame,
sash and mullion profile of required length with in 6 to 15 mm distance from the face of the
weld and then shall be screwed at 150mm from the end at every 400 mm (maximum) pitch
to Solid Foam uPVC profile so that it does not move or rattle.
26.13.8 Kitchen cabinet frame and shutter/Partition Hardware and Fittings

Materials for all hardware except for fixing shall have at least the equivalent corrosion resistance
of EN 1670-1988 grade 4 (240 hrs) when subjected to natural salt spray testing in accordance with
EN ISO 9227. Testing shall be carried out on complete hardware items and also duly approved by the
Engineer - in - charge before use at the site of work.

Hardware like hinges, rollers and locking devices which have been life cycle tested in accordance
with EN 199 (Windows and Doors - Resistance to repeated opening and closing - Test method) and
have achieved at least 10,000 operating cycles (i.e. opening and closing) without deterioration,
failure or excessive wear.
These shall be provided as per nomenclature of item of approved make and duly approved by
Engineer-in-Charge before fixing at site of work. Hardware / fittings such as handle, roller, touch lock,
multipoint locking, 3D hinges, friction hinges etc. shall be directly screwed not pre-drilled or hammered.
26.13.9 For kitchen cabinet frame and shutter/Partition

Approved quality stainless steel friction hinges (SS 304 grade) with SS screws shall be provided
as per nomenclature of item and length of friction hinges should cover more than 60 percent width of
the shutter and two number friction hinges required for each shutter one at top and one at bottom.
26.13.10 Tolerance
The tolerance in dimensions of finished kitchen cabinet frame and shutter/Partition in size shall
not be more than + 5mm from the approved drawing dimension.
(i) There shall be a maximum gap of 3 to 5mm in between Solid Foam uPVC door / window
frame and finished opening and the plastic packers shall be provided to maintain the level.
(ii) To maintain the exact dimension of door or window, the opening shall be checked for
dimension and orthogonally using a prefabricated template. Any defect shall be made good
by the agency at his own cost before fixing of door or window.
(iii) The Solid Foam uPVC frames are to be fixed in prepared opening in the walls. kitchen
cabinet frame and shutter/Partition shall be fixed into the aperture by drilling through the
outer frame to the existing structure and shall use 100 x 8mm fasteners of approved make.
(iv) The gap between Solid Foam uPVC kitchen cabinet frame and shutter/Partition and adjacent
RCC/Brick/Stone cladding work shall be filled with weatherproof Silicon sealant of approved
make to maximum 5mm depth and 5mmin width to allow expansion/contraction of Solid
Foam uPVC profiles. Silicon sealant of matching colour of Solid Foam uPVC profile shall be
applied over backer rod.
26.13.12 Precautions taken before installation of Solid Foam uPVC kitchen cabinet frame
and shutter/Partition
(i) Jambs, sills and soffits of the opening shall be finished with plaster / stone / tiles according
to agreement where Solid Foam uPVC kitchen cabinet frame and shutter/Partition to be
fixed.
(ii) Aperture shall be smooth in line and level as well as in plumb.
(iii) Flooring (where kitchen cabinet frame and shutter/Partition is to be installed should be
complete before installation of door).
(iv) Installation of Solid Foam uPVC kitchen cabinet frame and shutter/Partition should be done
before the last coat of the paint on the wall where window jambs, sills and soffits to be
finished by paint. Atleast one coat of paint should be done before installation begins.
(v) The colour of the profile shall be same and uniform on any surfaces or part of the surfaces
which may be visible after installation of the kitchen cabinet frame and shutter/Partition
fabricated from the profile, when viewed by the normal vision.

(vi) The Solid Foam uPVC profiles manufacturer shall provide warranty of 10 years for colour
fastness and any manufacturing defects in respect of Solid Foam uPVC profiles as well as
water and air tightness in case of casement Solid Foam uPVC kitchen cabinet frame and
shutter/Partition unit.
(vii) Solid Foam uPVC kitchen cabinet frame and shutter/Partition hardware and fittings
manufacturer shall provide warranty of 10 years for any manufacturing defects.
26.13.13 Mode of Measurement

The length and width of the kitchen cabinet frame and shutter/Partition shall be measured from
outer to outer face of the Solid Foam uPVC frame correct to a centimetre. Area shall be calculated in
square meter nearest to 0.01 square metres.
26.13.14 Rate
The rate includes the cost of all labour, material and T&P involved in all the operations described
above at all heights of the building. The cost of glass panes, wire mesh and silicon sealant shall be
paid separately.
26.14 REINFORCED SOIL RETAINING WALLS USING GEOGRIDS
26.14.1 General
The work shall include the design and construction of reinforced soil structures using geogrids.
Geogrids are defined as a geosynthetic reinforcement material consisting of connected paral-
lel sets of polymeric tensile ribs with apertures of sufficient size to allow strike-through of
surrounding soil, aggregate or other particulate matter. The ribs are called longitudinal and
transverse respectively, depending on the direction of major stress. The connection points of the
longitudinal and transverse ribs are called junctions / nodes. The openings in the geogrids, which
are usually, square, rectangular or oval, are called apertures.
The primary function of geogrid is soil reinforcement. In those applications where the direction of
major stresses are known, like reinforced walls & embankments, reinforced slopes, etc. unidirectional
or uniaxial geogrids are used. In applications where the stresses comefrom random directions in the
plane of the geogrid, bidirectional or biaxial grids are used. In addition, geogrids having three sets of
ribs, at 120° to each other, where strength is balanced along the three rib directions, are also available,
These are called triaxial geogrids, and may be used if the situation so demands.
In essence geogrids are of three types from the point of view of manufacturing process :
(a) Extruded Polyethylene (PE)or Polypropylene (PP) (uniaxial, biaxial or triaxial)
(b) Coated yarn of Polyester (polyethylene terephthalate-PET)or Polyvinyl Alcohol (PVA) coated
with PVC or latexor Bitumen or any such similar coating for purpose ofenvironmental
protection). The entanglement of the yarn at the nodes is an important parameter which
varies from product to product (unidirectional or bidirectional)for providing dimensional
stability to the product.
(c) High tenacity PET or PP straps or rods are overlapped longitudinally and transversely and
the junctions are ultrasonically or laser bonded to form stable geogrids (unidirectional or
bidirectional).
This specification does not cover the soil reinforcement works executed with metallic
reinforcement, or with geotextiles as reinforcement or natural fibre (coir or jute or bamboo)
reinforcement materials or with Geowebs / geocells.

It also does not cover ‘Hybrid’ systems, where multiple/ more than one type of
reinforcement product /system is used within the same structure.
Geogrids are used in the following applications :
(a) Sub-base / Foundation reinforcement
(b) Erosion control
(c) Reinforced Soil Walls and Slopes
(a) Sub-base / Foundation reinforcement :

Geogrids for use as reinforcement of sub-base of pavements or foundations shall be biaxial
grids and shall meet the requirements listed in Table 26.5 :
Table 26.5
Property Unit Stipulation Test Method
Stiffness @0.5% strain kN/m ≥ 350; both in MD and X-MD ISO 10319
Tensile strength @2% strain kN/m ≥ 15% of Tult; both in MD and X- ASTM D 6637
MD
Tensile strength @5% strain kN/m ≥ 20% of Tult; both in MD and X- ASTM D 6637
MD
Junction efficiency for extruded % ≥ 90% of rib ultimate tensile ASTM WK 14256
strength
Ultra-violet stability % ≥ 70% after 500 hrs exposure ASTM D 4355
Note : MD – Machine direction during manufacture

X-MD – Cross Machine direction during manufacture
All numerical values in the above Table represent MARV in the specified direction.
Minimum Average Roll Value (MARV) :
At least 6 sample rolls are taken from each lot of supply. “Lot” is defined by each quantum
of continuous supply or each quantum of continuous manufacture, whichever is less OR as
agreed between Engineer-in-Charge and contractor. From each of the rolls of material, at
least 8 specimen are taken and tested for the required property. The arithmetic average
over all specimen are calculated for each roll (average roll value). The minimum of the
averages denotes MARV.
Statistically, MARV is 2 standard deviations less than the mean of average roll values. If the
lot comprises more than 216 rolls, the number of samples should be ?(No. of rolls).
(b) Erosion control:
Detailed specifications for erosion control systems with geogrids shall be worked out as per
manufacturer’s specifications for the system adopted.
(c) Reinforced Soil Walls and Slopes :
Structures with faces steeper that 70° are considered as reinforced soil walls (RSW) (or
mechanically stabilized earth walls) and structures with face inclinations < 70° are considered
to be reinforced soil slopes (RSS). Some kind of facia system will be required for walls and
slopes steeper that 45°
All reinforced soil walls or slopes shall be executed based on approved designs and drawings
by the technical sanction authority. In case of EPC contracts, all generic specifications for
reinforced soil walls or slopes, to the extent deemed fit by NIT approving authority, shall be
made part of the tender document.

All reinforced soil walls and slopes having facia elements require connections between reinforcing
elements and facia. The design of facia including architectural / aesthetic considerations shall be
made part of the tender documents. Similarly, different manufacturers / vendors /solution providers
propose different forms of soil reinforcement to facia connectors. The strength, elongation at load
and durability of the connection shall be ascertained and generic requirements made part of the
tender document. The performance guarantee of the system as a whole shall inter alia include the
performance of facia and connectors.
In case of geonet or geocomposite drainage system provided in reinforced soil retaining walls or
slopes, the specifications for the same shall be provided separately as per the drainage requirement
and system adopted, based on manufacturer’s specifications. Guidance may be taken from ASTM
STP 1390 “Testing and Performance of Geosynthetics in Subsurface Drainage”. The different patterns
of Geo grids as shown in Fig 26.10, 26.11 and 26.12.
Reference may be made to IRC: SP:102-2014 “Guidelines for Design and Construction of
Reinforced Soil Walls” for guidance on design principles, construction issues, quality
control and common causes of failure of reinforced soil walls.
26.14.2 Physical and Mechanical Properties of Geogrids

26.14.2.1 General Requirements
The physical dimensional properties of the reinforcing elements like type of structure, rib/strap dimensions,
junction type, spacing between rib/strap, thickness of reinforcement elements, which vary from product to
product, can be readily measured for compliance with manufacturer’s specifications / data sheet. Some
physical properties like mass per unit area, roll width and length, weight of roll, etc. impact the logistical
issues like truckability, wastage, etc.
The manufacturers of geogrids shall have ISO – 9001 certification for manufacturing process and quality
control.
The product proposed to be used in the work shall have certification for use as soil reinforcing material
from an agency accredited for certifying geosynthetic reinforcement product.
The polymers used in the manufacture of soil reinforcing geogrids shall be virgin material.
The manufacturer shall provide third party test reports from NABL (or Geosynthetic Accreditation Institute
– Laboratory Accreditation Program [GAILAP]) accredited laboratories in India for quantity of geogrids beyond
a limit to be specified in the Notice Inviting Tender. The said limit will depend on quantum of work, its location,
urgency, availability of accredited laboratories, etc. For all quantities less than that, manufacturer’s test
certificate shall suffice. Test reports from IITs shall also be acceptable. In case of one laboratory not having the
entire gamut of facilities, different tests may be got done from separate tests facilities.
26.14.2.2 Physical Properties

Density of the PE, PP, PET or PVA material of extruded geogrids or bonded strap geogrids can be
measured using ASTM D 792 or ASTM D 1505. Coated PET yarn geogrids shall have molecular weight (ASTM
D 4603) not less than 25000 gm/mol (minimum) and Carboxyl End Group Content (ASTM D 7409) which
should not exceed 30 mmol/kg (maximum).
26.14.2.3 Engineering Properties of Geogrid

The following engineering properties are required to be provided for all types of geogrids intended to be
used in the work :
(i) Wide width tensile strength (ASTM D 6637 or ISO 10319) : This is the Short term strength or characteristic
strength (TCHAR) or ultimate tensile strength (TULT). It is taken as the MARV strength i.e. mean strength
less two standard deviations. Test for the ultimate tensile strength shall be carried out for each grade of
reinforcement. The test results shall be accompanied by stress – strain curves showing strength at 2 %
and 5% strain and strain elongation at failure.

(ii) Endurance properties denoted by the various reduction factors : The manufacturer shall
provide third party test reports from above mentioned laboratories / IITs for all the tests
needed to establish all the reduction factors listed below :
RFCR - Reduction factor for creep
RFID - Reduction factor for installation damage
RFW - Reduction factor for weathering
RFCH - Reduction factor for chemical / environmental effects
fS - Factor for the extrapolation of data. It caters to the statistical variation in the reduction
factors but does not consider the uncertainties of soil structure and calculation of loads.
All the above factors shall be determined in accordance with the provisions of ISO/TR
20432 – “Guide to the determination of long term strength of geosynthetics for soil
reinforcement”.
The Long Term design strength (LTDS)is determined as :
TD = TCHAR / R; where R = RFCR x RFID x RFW x RFCH x fS
(iii) Junction efficiency is defined as a percentage of junction strength determined in accordance
with ASTM D 7737 and single rib failure strength as per ASTM D 6637. It varies between 90
to 100% for extruded biaxial grids, 10 to 25% for woven or knit grids and 40 to 70% for
bonded strap grids.
For extruded biaxial or triaxial geogrids, the junction efficiency shall be 95% ± 2%
26.14.2.4 Project Specific Tests :

Annual average Daily Temperatures (AADT) / design temperature of the project site shall be
worked out and values of reduction factor for creep RFCR and for RFCH shall be provided as per
procedures given in ISO / TR -20432.
Also Tests shall be carried out to provide the following parameters for all grades of geogrids used in
the project :
(a) Pull-out coefficient as per ASTM D 6706 “Standard Test Method formeasuring Geosynthetic
pullout Resistance in Soil” and;
(b) Coefficient of interaction between reinforced fill soil and geogrids as per ASTM D 5321 – “
Standard Test Method for Determining the coefficient of soil and Geosynthetic or
Geosynthetic and Geosynthetic Friction by the Direct Shear Method” or as per IS :13326
: Part 1 – 1992 “ Method of test for the evaluation of interface friction between Geosynthetic
and soil : Part 1 Modified direct shear technique”.
One set of project specific tests shall be conducted at field or hird party accredited laboratory
or at any reputed institute like IITs, which may be mentioned in the tender.
26.14.3 Engineering Properties of Earth Fill

The fill material in the reinforced soil zone shall have drained or effective angle of friction not less
than 300 , measured in accordance with IS :2720 (Part 13), by conducting a drained direct shear test.
In case the fill material has 25 percent or more particles of 4.75 mm or larger, drained shear test
using large shear box may be conducted (IS :2720 : Part 39 : Section 1).
The Plasticity Index of the fill material shall be <6.
The gradation of fill soil shall be as per limits specified in Table 26.6

Table 26.6
Sieve Size Percentage Passing
75 mm 100%
425 micron 0 – 60%
75 micron < 15%
Materials with more than 15 percent passing 75 micron sieve, but less than 10 percent of particles
smaller than 15 microns are acceptable provided Plasticity Index (PI) is less than 6 and angle of
internal friction (∅) is not less than 30°.
Where Geosynthetic reinforcement material used is polyester yarn, the pH value of the fill material
shall be between 3 and 9. For Geosynthetic reinforcement material manufactured from PVA, PP and
HDPE, the pH value of the fill material shall be greater than 3. The pH value of the soil fill shall be
determined as per IS : 2720 (Part 26) – 1987 (Reaffirmed 2016)
Fly ash may be used as fill materials in reinforced soil walls provided its angle of internal friction
(∅) is not less than 30° and PI is less than 6. Reference may be made to IRC Guide lines on Use of
Fly ash in Road Embankments (IRC:SP-58).
Fly ash shall also satisfy requirements concerning pH values as above.
The fill materials used in the reinforced soil zone shall be free from organic or other deleterious
materials and shall not react adversely (chemically, electrically or biologically) with the reinforcement
material and / or facia material.
Properties of fill soil in the reinforced zone, unreinforced zone (or retained / back fill) soil and the
foundation soil shall be determined accurately during the construction phase, as per quality assurance
plans and directions of Engineer-in-Charge so as to ensure that these are the same as those
considered in the design.
The fill soil in the unreinforced zone shall also conform to the requirements specified in the
design.
26.14.4 Identification, Transportation, Storage and Handling

Geogrids shall be procured in roll form of width as per design requirement and with the prior
approval of the Engineer-in-Charge. All rolls shall have a protective cover with a label or tag (at
multiple locations and inside the core of the rolls in accordance with ASTM D 4873) specifying name
of the product, name of the manufacturer, roll number, date of manufacture and roll dimensions.
Material shall be protected from sunlight, mud, dirt, debris, any other harmful substances or
mechanical damage during transportation.
Rolls shall be stored in a secured area sufficiently elevated above the ground and adequately
covered to protect them from the following: Construction site damage, precipitation, prolonged exposure
to ultraviolet radiation including sunlight, chemicals that are strong acids or strong bases, flames
including welding sparks, high temperatures, and any other environmental conditions that may damage
the physical property values of the Geogrid.
Any material, which is damaged during transportation, handling or storage and do not meet the
minimum requirements of the specifications, rendering it unsuitable for use in the specific application,
is liable for rejection by the Engineer-in-Charge.

26.14.5 Failure Definition, System Responsibilty and Performance Bond
The design life, performance criteria and failure definitions shall be as per FHWA-NHI-10-024 and IRC :
SP : 102-2014. The design of reinforced soil wall or slope shall spell out the design life, performance criteria
and failure definitions. For example, the deformations of the wall / slope or any component thereof exceeding
the design values, any visible structural distress in any wall element, any subsidence of the top surface of
reinforced soil leading to distress in the infrastructure which is structurally dependent on the reinforced soil
wall or slope or foundation system, etc. are some conditions to be watched.
The decision of the Engineer-in-Charge as to the failure or otherwise of the reinforced soil wall or slope or
foundation system shall be final and binding on the contractor.
In case of failure, approved retrofitting measures may be adopted, duly vetted by expert institutions like
IITs, at the risk and cost of the contractor. The retrofitting measure shall be approved by the Engineer-in-
Charge.
Alternatively, and as a last resort, the whole or part of the structure, which has failed, shall be dismantled
and redone to the entire satisfaction of the Engineer-in-Charge.
If specified in the contract, the reinforced soil system performance shall be covered under performance
guarantee of the entire work, and no separate defect liability period or bond need be specified for the reinforced
soil structure. However, corporate guarantee for system performance for a period covering the Defect Liability
Period or more may be sought from the contractor.
26.14.6 Installation & Measurement for Payment

26.14.6.1 Site Preparation
The site shall be prepared by clearing, grubbing, and excavation or filling the area to the design grade.
This includes removal of topsoil and vegetation.
26.14.6.2 Foundation:
The foundation shall be aleveling pad of minimum 100mm width over and above the width of the facia
element, and 150mm thick M10 grade plain concrete, provided at a depth not less than 1000mm to receive the
facia elements and / or bottom most layer of reinforcement. The designer may provide higher specifications if
the situation at site so demands.
26.14.6.3 Laying of Geogrid

The geogrid shall be laid perpendicular to the face of the wall with greater cross sectional dimension in the
horizontal plane. The geogrid shall be laid stretched and smooth without wrinkles or folds on the prepared
subgrade (or within the granular subbase / base course if shown in the drawings) with the machine direction
oriented in the direction of major stress or as shown in the drawings. It shall be held taut by suitable arrangement
at site.
Geosynthetic uniaxial reinforcement shall be placed in continuous longitudinal rolls in the direction of the
main stress. Joints parallel to the wall shall not be permitted, except as shown on the working drawings.
Reinforcement coverage shall be a given percent of embedment area to be mentioned in the design / working
drawings, as per the type of reinforcement being used. Adjacent sections of geosynthetic reinforcement need
notbe overlapped or mechanically connected. In case of biaxial / triaxial reinforcement applications, overlap /
connections shall be as per manufacturer’s requirements.
On curves, the geogrid may be folded or overlapped to conform to the curves. The fold or overlap shall be
in the direction of construction and held in place by pins, staples, etc.
Prior to placing sub base / base course material the installed geogrid shall be inspected and approved by
the Engineer-in-Charge. Any minor damages shall be repaired by covering the damaged location with a geogrid
patch, which shall be mechanically connected to the parent reinforcement, as directed by the Engineer-in-
Charge.

26.14.6.4 Placing and Compacting Sub base/base course
The sub base or base shall be placed by end dumping onto the geogrid from the edge of the
geogrid or over previously placed sub base or base aggregate. The dumper shall move in reverse
direction over the spilled material.
Movement of construction equipment directly over the geogrid shall not be permitted. The grid
shall have a minimum compacted thickness of 150 mm over the grid before allowing movement of
vehicles, the speed of which shall be limited to 10 km/hr.
Sudden breaking and sharp turning of construction equipment shall be avoided on the first lift of
earth over the geogrid.
26.14.6.5 Specifications for Facia

The facing system shall be one of the following :
(a) Precast reinforced concrete panels:
The minimum thickness of precast concrete panels shall be 180 mm including facing textures,
logos and embellishments. The grade of concrete shall be minimum M35. The concrete
shall conform to the requirements of IS 456-2000.
Facia panel systems shall have provision of both horizontal and vertical gaps to prevent
concrete to concrete contact. The horizontal gap between the facing elements shall be
maintained by provision of Ethylene Propylene Diene Monomer (EPDM) pad.
The joints between the panels shall be covered from inside (inner face side)with non –
woven geotextile strips glued to the facing element ensuring full coverage of joints, to
prevent loss of aggregate filter material. Synthetic glue shall be used for this purpose. The
width of the geotextile strip shall not be less than 100 mm. This provision of covering of
panel joints with geotextile strips need not be followed if Geocomposite filter is used in
place of aggregate filter media.
All dimensions of the RCC panel facia elements shall be within ± 5mm, except thickness for
which tolerance shall be (+)5mm & (-) 0mm. Additionally, the evenness of the front face
shall be ± 5mm over 1500 mm length. The difference between length of the two diagonals
shall not be more than 5mm.
(b) Precast concrete interlocking blocks or Precast concrete hollow blocks:
Precast concrete blocks are dry cast and shall be manufactured from fully automatic block
making machines. The minimum grade of concrete shall be M 35 for all kinds of modular
blocks. In case of hollow blocks, the hollow area shall not exceed 40 percent of the cross
sectional area of the block. The outer side of the block shall have minimum thickness of
100mm.The hollow area shall however be filled with filter media.
The dimensional tolerance for length and width shall be ±2.5mm and for height ±1.5mm.
(c) Gabion facing:
Where gabion facia is used, it shall conform to the provisions of BS – 1:2010 and EN 14475
and made of mechanically fabricated double twisted hexagonal mesh. Wire used for the
double twisted mesh and selvedges shall be hot dip galvanized as per IS : 4826 – heavily
coated and soft type, with wire and mesh properties in accordance with EN – 10223 with
minimum Zn + alloy coating as per EN – 10244 and 0.5 mm thick PVC coating as per EN –
10245 and ISO – 527.
(d) Wrap around facia using geotextiles:
Where geosynthetics, including geogrids are used as wrap around facia, these shall form
a part of the reinforcing element. The wrap around shall have adequate length to resist pull
out and the wrap around length shall be calculated on the basis of safety in pull out. Wrap
around facia shall be protected by suitable means, against adverse effects of UV and other
elements of nature.

(e) Other proprietary and proven systems at the discretion of NIT approving authority
The facing material as well as the connections between facia and reinforcement shall be sufficiently
flexible to withstand any deformation of the fill and foundations.
The facia shall have an inward batter as shown in the drawings so that the tendency of the facia
panels to bulge outwards is countered.
Facia type adopted shall be given in the design and shown with complete details in the drawings.
The system supplier shall provide any test data to satisfy the Engineer-in-Charge regarding the
properties and suitability of the facia system adopted, if so required.
Where facia such as wrap around or gabion or welded wire and woven steel wire mesh facings
have been used and where climate conditions are appropriate, a green finish may be provided
where specified.
26.14.6.6 Connection between the Facia And Reinforcement

Connection between the facia panels and the reinforcing element shall be by using either nut or
bolt, HDPE inserts with bodkin joint, hollow embedded devices, polymeric/galvanized steel strips , /
rods,/pipes, / loop & toggle , fiber glass dowels or any other material shown in the drawings. The
connection between the panel and the reinforcement shall provide for 100 percent of the long term
design strength of the reinforcing element in continuity. Proprietary connections systems may be
provided as per design, subject to the condition that they are compliant with the design requirements
and durable.
In case of modular block facia and other type of facia such as gabion facia, where the reinforcement
is held by friction between the facia block and the reinforcement, the connection strength shall be
determined as per ASTM D 6638 :Standard Method of Test for Determining Connection Strength
between Geosynthetic Reinforcement and Segmental Concrete Units”.
The available connection strength shall satisfy the design requirements and shall not be less
than the maximum possible tensile force that the reinforcement layer under consideration may be
subjected to.
26.14.7 Measurement for Payment & Rates

(i) Reinforced Soil Wall :
The measurement for payment for reinforced soil wall shall be in square meters of finished
work of each face and shall be measured in the plane of final inclination specified in the
drawings. The measurement of length shall be the finished work along the length of the
road. The measurement of height along the slope shall be done from the top level of the
footing on which the facia element is placed to the top of the capping beam.
Measurement for friction slab and crash barrier shall be made separately.
(ii) Reinforced Soil Slope :
The measurement for payment for reinforced soil slope shall be in square meters of finished
work of each face and shall be measured in the plane of final inclination specified in the
drawings. The measurement of height along the slope shall be done from the top of the
leveling pad, where provided, to the top of the embankment. Where leveling pad is not
provided, the height shall be measured, in the final plane of inclination specified in the
drawings, from the bottom of the slope faceto the top of topmost facing element provided.
Measurement and payment of friction slab and crash barrier if provided shall be made
separately.

(iii) Rates:
The rate shall include cost of material, labour, plant and machinery, royalties, handling,
storage and transportation expenses, leveling pad, facia elements, coping beam, connectors,
reinforcing elements, scaffolding, all inclusive EXCEPTSupply and installation of the specified
filter media material, bed block, supply of soil fill for the reinforced as well as unreinforced
zone of the quality specified in the contract, placing, spreading and compaction through
mechanical means, which shall be measured separately.
No separate measurements for overlaps, wastages, or on any other account shall be admissible,
unless specifically provided for in the tender.
The rate shall include full compensation for design, drawings and testing of materials, as per
tender conditions.
The rate shall NOT include the cost of investigations, design and construction of ground
improvement measures, if required. The same shall be provided and paid as per NIT.
The payment for friction slab and crash barrier shall be made separately.
26.14.8 Design and Drawings:

The design of reinforced soil structure, the same shall be carried out in accordance with the
following standards as applicable :
(i) BS:8006-1-2010 “Code of Practice for Strengthened /Reinforced Soils and other Fills”.
(ii) IRC:SP:102-2014 “Guidelines for Design and Construction of Reinforced Soil Walls”.
(iii) FHWA – NHI-10-024 and FHWA – NHI-10-025 – “ Design and Construction of
Mechanically Stabilized Earth Walls and Reinforced Soil Slopes”
The design shall include the design of drainage system for the reinforced soil wall or slope or
foundation system.
26.14.9 Quality Control and Testing

The quality management system of the manufacturer shall conform to the requirements of ISO
9001:2015.
Manufacturer shall issue a test report stating minimum average roll values of material properties,
at the time of shipment from factory.
CE-certification should be required for supply of polymer geogrid material.
Manufacturer shall submit proof of having supplied to –

(i) One project in India having at least 80% of the tender quantity, OR
(ii) Two projects in India having at least 60% of the tender quantity, OR
(iii) Three projects in India having at least 40% of the tender quantity
The manufacturer shall submit project references if required by the Engineer-in-Charge.
In addition, at least one of the above qualifying projects shall have performed satisfactorily for at
least a 5-year period. Owner / Engineer’s certificate to that effect shall be submitted.
The NIT approving authority may, for recorded reasons, alter the above specifications
due to exigencies of work.

26.15 ALUMINUM PROFILE INDUSTRIAL TROUGHED SHEET ROOFING
26.15.1 MATERIALS
26.15.1.1 Aluminum profile industrial troughed sheet

These shall be made of alloy 31500/ 31000/40800 of thickness specified in the description of the
item and Chemical Composition of Wrought Aluminium and Aluminium Alloy Sheet and Strip shall
conform to IS 737. The weight of the sheet shall not be less than the value as per table 26.7.
Table 26.7
Thickness Weight of Sheet (Kg)

(mm)
Per Sqm. Sheet Per metre Length
920mm wide 1044mm wide
0.91 3.23 2.96 3.36
0.71 2.50 2.31 2.62
The sheets shall be free from cracks, split edges, twists, surface flaws etc. They shall be clean,
bright and smooth. The sheets shall not show signs of rust or white powdery deposits on the surface.
The corrugations shall be uniform in depth and pitch and parallel with the side.
26.15.1.2 Purlins
Purlins of the specified material or M.S. rolled sections of requisite size shall be fixed over the principal
rafters. These shall not be spaced at more than the following distances. (Table 26.8)
Table 26.8
Thickness of sheet Maximum spacing of purlins Maximum spacing of purlins
(intermediate) (ends)
0.71 mm 0.80 metre 0.55 metre
0.91 mm 1.20 metre 0.80 metre
The unsupported overhang sheets should not be more than 100mm and 150mm for the sheet
thickness of 0.71mm and 0.91mm respectively. The top surfaces of the purlins shall be uniform and
plane. They shall be painted before fixing on top. Embedded portions of wooden purlins shall be coal
tarred with two coats.
26.15.2 Slope
Roof shall not be pitched at a flatter slope than 1 vertical to 6horizontal. The normal pitch adopted
shall usually be 1 vertical to 4horizontal.
26.15.3 Laying and Fixing

The sheets shall be laid and fixed in the manner described below, unless otherwise shown in the
working drawings or directed by the Engineer-in-Charge.
The sheets shall be laid on the purlins to a true plane, with the lines of corrugations parallel or
normal to the sides of the area to be covered unless otherwise required as in special shaped roofs.
The sheets shall be laid with a minimum lap of 15 cm at the ends and 2 ridges of corrugations at
each side. The above minimum end lap of 15 cm shall apply to slopes of 1 vertical to 2 horizontal and
steeper slopes. For flatter slopes the minimum permissible end lap shall be 20 cm. The minimum lap

of sheets with ridge, hip and valley shall be 20 cm measured at right angles to the line of the ridge,
hip and valley respectively. These sheets shall be cut to suit the dimensions or shapes of the roof,
either along their length or their width or in a slant across their lines of corrugations at hips and
valleys. They shall be cut carefully with a straight edge chisel to give a smooth and straight finish.
Sheets shall not generally be fixed into gables and parapets. They shall be bent up along their
side edges close to the wall and the junction shall be protected by suitable flashing or by a projecting
drip course, the later to cover the junction by at least 7.5 cm.
The laying operation shall include all scaffolding work involved.
Sheets shall be fixed to the purlins or other roof members such as hip or valley rafters etc. with
fixed using self drilling/ self tapping SS screw (See Fig 26.13A & 26.13B) of size 5.5x65mm with
EPDM seal complete upto required pitch in horizontal, vertical or curves surfaces.
When fastening with self-drilling fasteners, it is imperative that the screw point has cleared the
substrate before the threads engage or the driller will actually pull the threads through the substrate
faster than it can be drilled, thereby breaking the fastener.
The bolts shall be sufficiently long so that after fixing they project above the top of the nuts by not
less than 10 mm. There shall be a minimum of three self drilling / self tapping placed at the ridges of
corrugations in each sheet on every purlin and their spacing shall not exceed 30 cm.
The self drilling/ self tapping SS screw shall be continuous and free from defects such as blisters,
flux stains, drops, excessive projections or other imperfections which would impair serviceability.
26.15.4 Finish
The roof when completed shall be true to lines, and slopes and shall be leak proof.
The length and breadth shall be measured correct to a cm. Area shall be worked out in sqm
The superficial area of roof covering shall be measured on the flat without allowance for laps and
corrugations. Portion of roof covering overlapping the ridge or hip etc. shall be included in the
measurements of the roof.
Roof with curved sheets shall be measured and paid for separately. Measurements shall be
taken on the flat and not girthed.
No deduction in measurement shall be made for opening upto 0.4 sqm and nothing extra shall be
allowed for forming such openings. For any opening exceeding 0.4 sqm in area, deduction in
measurements for the full opening shall be made and in such cases the labour involved in making
these openings shall be paid for separately. Cutting across corrugation shall be measured on the flat
and not girthed. No additions shall be made for laps cut through.
26.15.5 Rate
described above including all screws, seal, ridge, scaffolding, machinery for fixing and approved
sealant where required etc. but excluding the cost of purlins, rafters and trusses.

26.16 ECO FRIENDLY LIGHT WEIGHT CALCIUM SILICATE FALSE CEILING (TEGULAR EDGED)
26.16.1 Materials
26.16.1.1 Tiles
Eco friendly light weight calcium silicate tiles shall be made from Non-cementitious hydrated wet
moulded calcium silicate slurry/mixture, reinforced with fibers and natural fillers. Free from
formaldehyde and other harmful materials. Does not contain any toxic ingredients. Shall have
appropriate recycled material contents.
The Ceiling Tiles shall be of appropriate class and of finished thickness as specified in the
description of the item .Only selected tiles of uniform width shall be used. Unless otherwise specified
in the description of the item or shown in the drawings, the width of tiles selected for use shall not be
less than 595 X 595 mm in size and shall be 15 mm thick integral densified tegular edged type, light
weight wet moulded calcium silicate.
Where width of room/ corridor is in multiple of standard width of tiles, same pattern shall be
maintained throughout the length. Where the width of rooms/ corridor is not in multiple of standard
width of tiles, borders with appropriate width and material of boards shall be provided in design
approved by the Engineer-in-charge and maintained uniformly throughout of the length/ width of
room/ corridor. Eco Friendly Light Weight Calcium silicate tiles shall have the following properties:
(a) Surface: All tiles are prime coated on both sides. Standard finish in two coats white dispersion
type, solvent free paint.
(b) Dimensions:
595mmx595mmx15mm thick tegular edged. Size referred to are always module sizes. The
nominal panel size may differ depending on the suspension system used.
(c) Thickness: 10 mm thick in the center and 15mm thick all around on edge resting portion
with integral densified edge.
(d) Density of material: 350 kg per cum in the central 10 mm thick portion and 450 kg cum on
the edges, (Average 370 kg per cum as per ECBC Code 2007).
(e) Relative humidity: 100% RH resistant.
(f) Fire resistance: Non-combustible as per BS:476 Part-4. Fire performance: as per BS:476
(Part-6) for fire propagation and BS 476 (Part 7) for Surface spread of flame.
(g) Thermal conductivity: 0.048 W/m- K - 0.052 W/m- K as per ECBC Code 2007 and ASTM
518-1991.
(h) Recycled Content: Shall have 46-50% recycled content out of which 18-20% should be
FLYASH.
(i) Acoustic control: Sound Attenuation 30-32dB
Noise reduction coefficient (NRC)
Plain & Designer tile: 0.10-0.15.
For Pin Hole/Texture pattern tiles: 0.20-0.30.
Pin hole/Texture fully perforated tile: 0.30-0.40.
For 5mm fully perforated 0.40-0.50.
For 5mm fully perforated with 50mm/48gsm glass wool 0.65-0.85.

(J) Light reflectance: >85%.
(k) Weight: 5 - 5.5Kg/m2.
(l) Suspension system: Suspension system shall be made of roll-formed hot-dipped
galvanized steel.
26.16.1.2 Frame
Frame is made up of interlocking metal T-grid of hot dipped galvanized steel sections of 0.33mm
thick (Galvanized @ 120 gms/m2 including all sides) comprising of main T runners of size 24 x 38mm
of length 3000mm, cross T of size 24 x 32 mm of length 1200mm and secondary intermediate cross
T of size 24 x 32mm of length 600mm to form grid modules of size 600 x 600mm. This grid shall be
suspended from ceiling using galvanized mild steel members (Galvanized @ 80 gms/m2 including all
sides) i.e. 12x50mm long dash fasteners, 6mm dia fully threaded hanger rod upto 1000 mm length
and L-shaped level adjuster of size 76 x 25 x 25x 1.6mm fixed with grid and Z cleat of size
25x37x25x1.6mm thick with precut hole on both 25mm flange to pierce into 12x50mm or even bigger
dash fastener if require. Frame also consist of galvanized iron perimeter wall angle of size 24 x 24 x
0.40mm of length 3000mm to be fixed on periphery wall/ partition with the help of plastic rawl plugs at
450mm centre to centre and 40mm long dry wall SS screws.
The bottom surface of the frame shall be checked and corrected to true plans and slopes.
26.16.2 Fixing
Outer wall angle shall be fixed accurately and truly at required height and level, parallel and
close to the wall. Thereafter all the T members shall be placed and fixed carefully to form the grid.
The grid comprises of main T-runners at 1200mm centres securely fixed to the structural soffit by
approved and adjustable hanger rods at 1200mm maximum centres and not more than 150mm from
spliced joints of main T-runners. The last hanger at the end of each runner should not be greater
than 600mm from the adjacent wall. Similarly, cross T-runners of 1200mm length shall be placed at
600mm centre to centre. 600x600mm modules to be formed by fitting 600mm long flush fitting cross
Tees (secondary cross T) centrally between 1200mm cross T-runners. The tiles shall then be placed
properly in the grids as per required pattern, texture and design/ drawing and as per directions of the
Engineer-in-Charge. If required, level of the false ceiling grid shall be checked after placing of
calcium silicate tiles and necessary adjustment shall be made wherever required through level adjuster.
26.16.3 Precaution:
(a) All wet trades such as plastering, conduting and painting etc, be completed prior to start of
false ceiling works.
(b) Air conditioning duct work is to be completed preferably even before the suspension of the
grid section.
(c) Electrical chasing or drawing lines & cables, etc are to be in place before start of false
ceiling work.
(d) No unauthorized weight is put on false ceiling. Lighting fixtures, diffusers are to be suspended
independently with proper chain/wire & dash fasteners as directed by Engineer In Charge/
manufacturer guide line.
(e) The area is dry prior to ceiling installation work.
26.16.4 Finishing
Care should be taken while placing Light Weight calcium silicate tiles into the grid so that there
will be no displacement to grid and stains/ dirty marks put by the workers. (worker should preferably
wear clean soft cotton gloves while placing tile).

Length and breadth shall be measured correct to a cm. Areas shall be worked out to nearest
0.01sqm. The superficial area of the finished work ceiling shall be measured in square meters. No
deduction in measurements shall be made for openings of areas upto0.36 Sqm. Nothing extra shall
be payable either for any extra material or labour involved in forming such openings. For openings
exceeding 0.36 sqm in area, deductions in measurements for the full opening in multiple of area of
each tile (0.36 Sqm) will be made.
26.16.6 Rate
above.
26.16.7 MTC: Manufacturers test certificate/ report of invoice to be submitted for every delivery
challan by suppliers.
26.17 ECO FRIENDLY LIGHT WEIGHT CALCIUM SILICATE FALSE CEILING (MICRO LOOK
EDGE) (Fig . 16)
26.17.1 Materials
26.17.1.1 Tiles
Eco friendly light weight calcium silicate tiles shall be made from Non-cementitious hydrated calcium
silicate slurry/mixture, reinforced with recycled material and natural fillers. Free from formaldehyde
and other harmful materials. does not contain any toxic ingredients.
Tiles shall be appropriate class and of finished thickness as specified in the description of the
item. Only selected tiles of uniform width shall be used. Unless otherwise specified in the description
of the item or shown in the drawings, the width of tiles selected for use shall not be less than 595 x
595mm in size and of approved texture, design and patterns and patterns and shall be 15mm thick
integral densified micro-edged type light weight calcium silicate.
room/ corridor. Calcium silicate tiles shall have the following properties:
(b) Dimensions:
595mm x 595mm x 15mm thick integral densified micro-edge. Size referred to are always
module sizes. The nominal panel size may differ depending on the suspension system
used.
(C) Thickness: 10 mm thick in the center and 15mm thick all around on edge resting portion
with micro look integral densified edge.

518-1991.
FLYASH.
(j) Light reflectance: >85%.
(l) Suspension system: Suspension system shall be made of roll-formed hot-dipped
galvanized steel.
26.17.1.2 Frame
Frame is made up of interlocking metal pre coated T-grid of hot dipped galvanized steel sections
of 0.40mm thick on Silhouette profile comprising of main T runners of size 15 x 42mm of length
3000mm, cross T of size 15 x 42mm of length 1200mm and secondary intermediate cross T of size 15
x 42mm of length 600mm to form grid modules of size 600 x 600mm. This grid shall be suspended
from ceiling using galvanized mild steel members (Galvanized @ 80 gms/m2 including all sides) i.e.
12x50mm long dash fasteners, 6mm dia fully threaded hanger rod upto 1000 mm length, L-shaped
level adjuster of size 76 x 25 x 25x 1.6mm fixed with grid and Z cleat of size 25x37x25x1.6mm thick
with precut hole on both 25mm flange to pierce into 12x50mm or even bigger dash fastener if required
Frame also consist of galvanized iron perimeter wall angle of size 22 x 19 x 0.40mm of length 3000mm
to be fixed on periphery wall/ partition with the help of plastic rawl plugs at 450mm centre to centre
and 40mm long dry wall SS screws.
26.17.2 Fixing

26.17.3 Precaution:
a. All wet trades such as plastering, conduting and painting etc, be completed prior to start of
false ceiling works.
b. Air conditioning duct work is to be completed preferably even before the suspension of the
grid section.
c. Electrical chasing or drawing lines & cables etc are to be in place before start of false
ceiling work.
d. No unauthorized weight is put on false ceiling. Lighting fixtures, diffusers are to be suspended
independently with proper chain/wire & dash fasteners as directed by Engineer In Charge/
Manufacturer guide line
e. The area is dry prior to ceiling installation work.
26.17.4 Finishing
deduction in measurements shall be made for openings of areas upto0.36 Sqm. extra shall be
payable either for any extra material or labour involved in forming such openings. For openings
26.17.6 Rate
above.
26.18 ECO FRIENDLY LIGHT WEIGHT CALCIUM SILICATE WALL PANELLING

(FULLY PERFORATED SQUARE/ BUTT EDGED) (Fig . 17)
26.18.1 Materials
26.18.1.1 Tiles
Eco Friendly Light Weight Calcium silicate tiles shall be made from Non-cementitious hydrated
calcium silicate slurry/Mixture, reinforced recycled material with fibers and natural fillers. Free
from formaldehyde and other harmful materials. Does not contain any toxic ingredients.
595mm in size and of approved texture, design and patterns and patterns and shall be 15mm thick
fully perforated square/ butt edged type.

Where width and height of room is in multiple of standard width of tiles/panels, same pattern shall
be maintained throughout the length. Where the width and height of rooms is not in multiple of
standard width of tiles, cut tile of same design shall be used, material of tile shall be provided in
design approved by the Engineer-in-charge and maintained uniformly throughout of the length /
height of room.
Calcium silicate tiles shall have the following properties:

(b) Dimensions: 595mmx595mm Butt look Edged. The nominal panel size may differ where
cut tile are used to make similar pattern
(c) Density of material: 350 kg per cum in the central 10 mm thick portion and 450 kg cum on
the butt edge, (Average 370 kg per cum as per ECBC Code 2007).
(d) Relative humidity: 100% RH resistant.
(e) Fire resistance: Non-combustible as per BS:476 Part-4. Fire performance: as per BS:476
(f) Thermal conductivity: 0.048 W/m- K - 0.052 W/m- K as per ECBC Code 2007 and ASTM
518-1991.
(g) Recycled Content: Shall have 46-50% recycled content out of which 18-20% should be
FLYASH.
(h) Acoustic control: Sound Attenuation 30-32dB
For 5mm fully perforated with 50mm/48 kg3 density glass wool 0.65-0.85.
(i) Light reflectance:>85%.
(j) Weight: 5 - 5.5Kg/m2
(k) Glass Wool: (to be procured separately by installer 50mm thick of density 48 Kg/m3
shall be inserted uniformly before laying the tiles/panels.
(l) Framing system: Framing system shall be made from especially fabricated galvanized mild
steel sheet of 0.50mm thick pressed sections.
26.18.1.2 Frame
Framing system shall be made from especially fabricated galvanized mild steel sheet of 0.50mm
thick pressed sections having hot dipped galvanizing @120gms/m2 including all sides. Framing system
comprising of vertical studs of size 48 x 34 x 36mm, ceiling channel section of size 50 x 32mm fixed to
the floor and soffit at 600mm centres and the channel section of size 50 x 32mm is then to be fixed in
horizontal direction at 600mm centre to centre so as to form a grid of 600 x 600mm. .
The surface of the frame shall be checked and corrected to true verticality and slopes if any.
26.18.2 Fixing
Framing system shall be made from especially fabricated galvanized mild steel sheet of 0.50mm
thick pressed sections having hot dipped galvanizing @120gms/m2 including all sides. Framing system
comprising of vertical studs of size 48 x 34 x 36mm placed at 600mm centre to centre in a floor and

ceiling channel section of size 50 x 32mm fixed to the floor and soffit at 600mm centres using 12mm
dia, 50mm long wedge type expanded zinc alloy dash fastner with 10mm bolt. This channel is then to
be fixed in horizontal direction at 600mm centre to centreso as to form a grid of 600 x 600mm.Glass
wool of 50mm thickness and of density 48 Kg/m3 is then to be inserted in the slot. Finally, calcium
silicate tile/ panels are to be screw fixed with self-tapping pan head nickel coated M S screws of size
13 x 3.2mm on the grid leaving an even groove of 1mm between the panels/ tiles as per required
pattern, texture and design/ drawing, preferably start from 2.5/4.0ft/window sill height or as per directions
of the Engineer-in-Charge. Joint between the tiles/ panels are then be jointed and finished using
recommended jointing calcium silicate based compound and fibre joint tape roll of 50 mm wide and
two coats of primer suitable for paneling.
26.18.3 Finishing
Care should be taken while fixing Calcium Silicate Wall Panels / Butt edge tiles on the framing
system, so that these are even surface, and no undulations are seen, nor the paint remains visible in
the perforations, and no dirt marks are visible, (worker should preferably wear clean soft cotton
gloves while placing tile).
0.01sqm. The superficial area of the finished work paneling shall be measured in square meters. No
26.18.5 Rate
above.
26.19 CALCIUM SILICATE FALSE CEILING (TEGULAR EDGED- FIXED TO EXISTING T-FRAME)
26.19.1 Materials
26.19.1.1 Tiles
Eco friendly light weight calcium silicate tiles shall be made from Non-cementitious hydrated wet
moulded calcium silicate slurry/mixture, reinforced with fibers and natural fillers. Free from
formaldehyde and other harmful materials. Does not contain any toxic ingredients. Shall have
appropriate recycled material contents.
The Ceiling Tiles shall be of appropriate class and of finished thickness as specified in the
description of the item .Only selected tiles of uniform width shall be used. Unless otherwise specified
in the description of the item or shown in the drawings, the width of tiles selected for use shall not be
less than 595 x 595 mm in size and shall be 15 mm thick integral densified tegular edged type, light
weight wet moulded calcium silicate.

room/ corridor. Calcium silicate tiles shall have the following properties:
(b) Dimensions:
595mmx595mmx15mm thick tegular edged. Size referred to are always module sizes. The
nominal panel size may differ depending on the suspension system used.
(c) Thickness: 10 mm thick in the center and 15mm thick all around on edge resting portion
with integral densified edge.
518-1991.
FLYASH.
(j) Light reflectance: >85%.
26.19.1.2 Frame
Frame is already exists at site. The bottom surface of the frame shall be checked and corrected
to true plans and slopes.
26.19.2 Fixing
The tiles shall be placed properly in the grids already exists at site, as per required pattern,
texture and design/ drawing and as per directions of the Engineer-in-Charge/manufacturer guide
line. If required. level of the false ceiling grid shall be checked after placing of calcium silicate tiles
and necessary adjustment shall be made wherever required through level adjuster.

26.19.3 Finishing
26.19.5 Rate
above.
26.20 GLASS FIBRE REINFORCED GYPSUM (GRG) FALSE CEILING (SEMI PERFORATED MICRO
TEGULAR EDGED)
26.20.1 Materials
26.20.1.1 Tiles
Glass fibre Reinforced Gypsum (GRG) false ceiling tiles shall be made of Gypsum plaster of 75
microns particle size mixed with short length glass fibre filament of 20 microns ± 5 microns diameter
to give it high strength and shall be free from harmful or any toxic ingredients.
595mm in size and of approved texture, design and patterns and patterns and shall be semi perforated
12mm thick micro tegular-edged type GRG tiles.
room/ corridor. GRG tiles shall have the following properties:
(a) Surface: The GRG false ceiling tiles shall be painted with white dispersion type solvent
free paint.
(b) Dimensions: 595mm x 595mm Semi perforated 12mm thick micro tegular-edged type GRG
tiles. Size referred to are always module sizes. The nominal panel size may differ depending
on the suspension system used.
(c) Density of material: 700 to 850 kg per Cum.
(d) Relative humidity:99% RH resistant.
(e) Fire resistance: Non-combustible as per BS:476, Part-4: 1970

(f) Moisture Content: < 2%
(g) Acoustic control: Noise reduction coefficient (NRC) = 0.50 to 0.75 as per IS: 8225-1981.
(h) Light reflectance:>85%
(i) Suspension system: Suspension system shall be made of interlocking metal T-grids of
hot-dipped galvanized iron section.
26.20.1.2 Frame
Frame is made up of interlocking metal T-grids of hot dipped galvanized steel sections of 0.33mm
thick(Galvanized @ 120 grams per sqm including both sides) comprising of main T runners of size 15
x 32mm of length 3000mm, cross T of size 15 x 32mm of length 1200mm and secondary intermediate
cross T of size 15 x 32mm of length 600mm to form grid modules of size 600 x 600mm. This grid shall
be suspended from ceiling using galvanized mild steel members (Galvanized @ 80 gms/m2 including
all sides) i.e. 50mm long, 8mm outer diameter M-6 dash fasteners, 6mmdia fully threaded hanger rod
upto 1000 mm length and L-shaped level adjuster of size 85 x 25 x 2mm. Frame also consist of
galvanized iron perimeter wall angle of size 24 x 24 x 0.40mm of length 3000mm to be fixed on
periphery wall/ partition with the help of plastic rawl plugs at 450mm centre to centre and 40mm long
dry wall SS screws.
26.20.2 Fixing
Outer wall angle shall be fixed accurately and truly at required height and level, parallel and close
to the wall. Thereafter all the T members shall be placed and fixed carefully to form the grid. The grid
comprises of main T-runners at 1200mm centres securely fixed to the structural soffit by approved and
adjustable hanger rods at 1200mm maximum centres and not more than 150mm from spliced joints of
main T-runners. The last hanger at the end of each runner should not be greater than 600mm from the
adjacent wall. Similarly, cross T-runners of 1200mm length shall be placed at 600mm centre to centre.
600x600mm modules to be formed by fitting 600mm long flush fitting cross Tees (secondary cross T)
centrally between 1200mm cross T-runners. The tiles shall then be placed properly in the grids as per
required pattern, texture and design/ drawing and as per directions of the Engineer-in-Charge. If
required, level of the false ceiling grid shall be checked after placing of semi perforated GRG tiles and
necessary adjustment shall be made wherever required through level adjuster.
26.20.3 Finishing
Care should be taken while placing semi perforated GRG tiles into the grid so that there will be no
displacement to grid and stains/ dirty marks put by the workers.
0.01sqm. The superficial area of the finished work ceiling shall be measured in square metres. No
26.20.5 Rate
above.

26.21 GLASS FIBRE REINFORCED GYPSUM (GRG) FALSE CEILING (FULLY PERFORATED
MICRO TEGULAR EDGED)
26.21.1 Materials
26.21.1.1 Tiles
Glass fibre Reinforced Gypsum (GRG) false ceiling tiles shall be made of Gypsum plaster of 75
microns particle size mixed with short length glass fibre filament of 20 microns ± 5 microns diameter
to give it high strength and shall be free from harmful or any toxic ingredients.
595mm in size and of approved texture, design and patterns and patterns and shall be fully perforated
12mm thick micro tegular-edged type GRG tiles.
room/ corridor. GRG tiles shall have the following properties:
(a) Surface: The GRG false ceiling tiles shall be painted with white dispersion type solvent
free paint. fully perforated GRG false ceiling tiles shall have a non-woven fabric of density
minimum 30 grams per square meter pasted at the back.
(b) Dimensions: 595mm x 595mm Fully perforated 12mm thick micro tegular-edged type GRG
tiles. Size referred to are always module sizes. The nominal panel size may differ depending
on the suspension system used.
(c) Density of material: 700 to 850 kg per Cum.
(d) Relative humidity:99% RH resistant.
(e) Fire resistance: Non-combustible as per BS: 476, Part-4: 1970
(f) Moisture Content: < 2%
(g) Acoustic control: Noise reduction coefficient (NRC) = 0.50 to 0.75 as per IS: 8225-1981.
(h) Light reflectance:>85%
hot-dipped galvanized iron section.
26.21.1.2 Frame
Frame is made up of interlocking metal T-grids of hot dipped galvanized steel sections of 0.33mm
thick (Galvanized @ 120 grams per sqm including both sides) comprising of main T runners of size 15 x
32mm of length 3000mm, cross T of size 15 x 32mm of length 1200mm and secondary intermediate cross
T of size 15 x 32mm of length 600mm to form grid modules of size 600 x 600mm. This grid shall be
suspended from ceiling using galvanized mild steel members (Galvanized @ 80 gms/m2 including all
sides) i.e. 50mm long, 8mm outer diameter M-6 dash fasteners, 6mm dia fully threaded hanger rod upto
1000 mm length and L-shaped level adjuster of size 85 x 25 x 2mm. Frame also consist of galvanized iron
perimeter wall angle of size 24 x 24 x 0.40mm of length 3000mm to be fixed on periphery wall/ partition with
the help of plastic rawl plugs at 450mm centre to centre and 40mm long dry wall SS screws.

26.21.2 Fixing
Engineer-in-Charge. If required, level of the false ceiling grid shall be checked after placing of semi
perforated GRG tiles and necessary adjustment shall be made wherever required through level
adjuster.
26.21.3 Finishing
Care should be taken while placing semi perforated GRG tiles into the grid so that there will be no
26.21.5 Rate
above.
26.22 MINERAL FIBRE FALSE CEILING (BEVELED TEGULAR MINERAL FIBRES)
26.22.1 Materials
26.22.1.1 Tiles
Mineral Fiber Ceiling Tiles shall be made of granulated high-density Mineral Wool as the main
material and top production technique which gives it superior features of fire-proofing, sound
absorption, heat insulation & sag resistance. They are cost effective and are mainly used for acoustics
and decoration.
595mm in size and of approved texture, design and patterns and patterns and shall be of 16mm/
20mm thick Beveled Tegular edge type.
room/ corridor. Mineral Fibre tiles shall have the following properties:
(a) Surface: Shall be of approved texture, design and pattern.

(b) Dimensions: 595mm x 595mm x 16mm (20mm) thick Beveled Tegular edge type. Size
referred to are always module sizes. The nominal panel size may differ depending on the
suspension system used.
(c) Relative humidity:99% RH resistant.
(d) Fire resistance: Fire performance as per BS:476 (Part-6 & 7)
(e) Thermal conductivity: 0.052 W/m–K – 0.057 W/m–K
(f) Acoustic control: Noise reduction coefficient (NRC) = 0.50 to 0.60
(g) Light reflectance:>85%.
(h) Weight: 3.10 Kg/m2 (for 16mm thick) & 5.29 Kg/m2 (for 20mm thick)
hot-dipped all round galvanized steel.
26.22.1.2 Frame
Frame is made up of interlocking metal T-grids of hot dipped all round galvanized steel sections
of 0.33mm thick (Galvanized @ 120 grams per sqm including both sides) comprising of main T
runners of size 15 x 32mm of length 3000mm, cross T of size 15 x 32mm of length 1200mm and
secondary intermediate cross T of size 15 x 32mm of length 600mm to form grid modules of size 600
x 600mm. This grid shall be suspended from ceiling using galvanized mild steel members (Galvanized
@ 80 gms/m2 including all sides) i.e. 50mm long, 8mm outer diameter M-6 dash fasteners, 6mmdia
fully threaded hanger rod upto 1000 mm length and L-shaped level adjuster of size 85 x 25 x 2mm.
Frame also consist of galvanized iron perimeter wall angle of size 24 x 24 x 0.40mm of length 3000mm
to be fixed on periphery wall/ partition with the help of plastic rawl plugs at 450mm centre to centre
and 40mm long dry wall SS screws.
26.22.2 Fixing
26.22.3 Finishing
Care should be taken while placing calcium silicate tiles into the grid so that there will be no

26.22.5 Rate
above.
26.23 MINERAL FIBRE FALSE CEILING (BEVELED TEGULAR MINERAL FIBRE ANTI-MICROBIAL)
Specification for the mineral fibre false ceiling using 16 mm Beveled Tegular Mineral Fibre Anti-
microbial is same as 16 mm Beveled Tegular Mineral Fibres specified in above clause 26.22.
26.24 CHIPPING OF UNSOUND / WEAK CONCRETE:

26.24.1 Precaution, Preparation and procedure
The Chipping of unsound work / concrete / delaminated layer of gunniting etc. shall be done by
chipping( after properly supporting the member with false works) , in regular shape, with sides
parallel or normal to the direction of the reinforcement. The chipping shall be done minimum 50 mm
beyond the perimeter of the spell. For a single spell, the repair area should have a minimum width of
100 mm in any direction. If a number of spells are closely located to each other, these should be
included in a single area marked for repair. The cut shall be made normal to the surface of member.
The minimum depth of cut should be 12 mm.
Adequate care is to be taken not to cut the reinforcement steel and a cover metre could be used
to estimate the depth of cover, for which nothing extra shall be paid.
Chipping should be done upto the required depth as decided by the Engineer-in- Charge to
produce sound concrete surface to a near uniform depth for the repair areas.
Removal of concrete should begin at the interior of the repair areas and progress towards the
boundaries. All edges and cavities shall be square shouldered.
Dimensions of area chipped off for RCC slabs, beams, columns etc. shall be measured in
centimeters after the chipping / dismantling operation is completed for different thicknesses as
specified in the item separately. The area of the chipped / exposed RCC surface shall be measured
in sq. m correct to second place of decimal for different thicknesses as specified in the item separately
.
26.24.3 Rate:- The rate shall include the cost of all the T&P required, labour involved and cost of
all the operations as described above.
26.25 CLEANING OF EXISTING REINFORCEMENT AND PASSIVATING ITS SURFACE

26.25.1 Material:-
The alkaline chemical rust remover as approved by the Engineer-in Charge and should be
procured in sealed containers indicating the batch number and the date of manufacture etc.
26.25.2 Surface preparation-

The rust has to be removed from the surface of the reinforcement manually using chisels, wire
brush, emery paper etc. as directed by Engineer-in-Charge at no extra cost, till the steel surface is
cleared of all rust that could be removed manually or mechanically.

26.25.3 Application:-
Then alkaline chemical rust remover, as approved by the Engineer-in Charge shall be applied
with brush over the reinforcement surface thoroughly along the full length of rusted reinforcement.
After 24 hours of its application the surface shall be cleaned with wire brush and all loose particles
removed. It should then be washed clean, with water, thoroughly and allowed to dry. alkaline chemical
rust remover should be applied to the reinforcement approximately one litter for 6 to 7 sqm. Of the
steel area (assuming the surface of the reinforcement of rough) the consumption of the alkaline
chemical rust remover should be about 0.40 liters per 10 Sqm. Area of RCC unit.
26.25.4 Measurements: - The length of the reinforcement bar cleaned shall be measured
correct to a centimeter in two categories i.e. i) Bars upto 12mm dia. ii) Bars above 12mm dia.
26.25.5 Rates :- shall include cost of all materials, labour, T&P etc. involved in all the operations
as described above.
26.26 DRILLING SUITABLE HOLES IN RCC OR PLAIN CEMENT CONCRETE

26.26.1 Preparation and Procedure
For introducing additional reinforcement bars for new structural connections or supplementing
additional steel area to the existing RCC member, the cross sectional area ( diameter and no. of
bars) and length required shall be approved by the Engineer-in-Charge. Also the depth of embedment
of reinforcement bar shall be approved by the Engineer-in-Charge. The holes have to be power
drilled in RCC. The drilled hole in dry state has to be cleaned with round brush and by blowing air
through a tube inserted in the hole and connected to hand operated blower.
Then epoxy is to be injected from foil pack with help of epoxy dispenser and epoxy cartridge holder
and disposable PVC mixing nozzle inserted inside the drilled hole to fill it from bottom of hole and
upwards. Then the reinforcement bar is to be inserted and allowed to remain undisturbed for minimum
24 hours and allow epoxy adhesive to be air cured. Epoxy resin anchor grout shall be approved by
the Engineer-in Charge.
26.26.2 Measurements:- Holes shall be enumerated.
26.26.3 Rates :- Shall include cost of all inputs of material, labour and T&P etc. involved in all the
operations except the cost of reinforcement.
26.27 BONDING COAT

26.27.1 Material:- SBR polymer modified cementitious bond coat and epoxy bonding adhesive
shall be approved by the Engineer-in Charge.
26.27.2 Surface Preparation:-

Bonding coat is required to be applied for adhesion of applied repair concrete or mortar to the
parent concrete. For this, the surface should be thoroughly cleaned by brushes and by blowing air
from hand operated pump. The surface shall then be saturated with water (but without excess water).
26.27.3 Application:-
The components of bonding coat shall be weigh batched and mixed in specific proportions, in a
clean container, as directed by the Engineer-in-Charge. They should then be blended to a uniform
and homogeneous mixture, lump free and of creamy consistency.

The specified bond coat should be applied by stiff nylon bristle brush. The bonding material
should be worked well onto the concrete surface of the parent concrete including reinforcement
surface ensuring that no pinholes are visible. The SBR polymer modified bonding cement slurry shall
be applied to a thickness not more than 2 mm. A second coat shall be applied within 15 to 20 minutes
of application of the first coat at right angles to the first coat to ensure complete coverage and
absence of pin holes.
Area of exposed RCC unit shall be measured in sqm correct to two decimal places for the purpose
of payment.
26.27.5 Rates :-
Shall include cost of all inputs of material, labour and T&P etc. involved in all the operations as
described above.
26.28 PROVIDING, MIXING AND APPLYING SBR POLYMER MODIFIED CEMENT MORTAR
26.28.1 Procedure and application
Fresh mortar shall be applied while the bond coat is still tacky and well within setting period. If
adhesive cured to the extent of loosing its tack or has set before mortar is applied. The same shall be
removed or slightly abraded and another coat of bond coat shall to be applied by the contractor at
his own cost. Freshly placed mortar shall be thoroughly consolidated to ensure full bonding of the
fresh mortar with the parent concrete. If there is a failure of bond of fresh mortar/ plaster with parent
concrete surface and it sounds hollow on tapping, the repair work shall be dismantled and redone by
the contractor at his own cost and to the entire satisfaction of the Engineer-in-Charge.
26.28.2 Testing : 75mm size cube of the mortar, crushing strength at the end of 28 days to be not
less than 30 N/Sqmm2.
26.28.3 Measurement
Length and breadth of the application shall be measured correct to a cm and area worked out to
in sqm upto 2 decimal places, separately for different thicknesses specified in the item.
26.28.4 Rates
Rates shall include all the materials, labour, T&P in all the operations as described above.
26.29 APPLYING SBR POLYMER MODIFIED CEMENT CONCRETE FOR STRUCTURAL MEMBERS
26.29.1 Material: SBR polymer or equivalent material shall be approved by Engineer-in-charge.
26.29.2 Preparation & application

After bonding coat pre fabricated shuttering shall then be erected immediately. Fresh concrete
shall be placed /applied while the bond coat is still tacky and well within pot - life / setting period. If
adhesive cures to the extent of loosing its tack or has set before concrete is placed / applied, the same
shall be removed or slightly abraded and another coat of adhesive / bond coat shall have to be
applied by the contractor at his own cost. Freshly placed concrete shall be thoroughly consolidated to
ensure full bonding of the fresh concrete with the parent concrete. If there is a failure of bond of fresh
concrete with parent concrete surface and it sounds hollow on tapping, the repair work shall be dismantled
and redone by the contractor at his own cost and to the entire satisfaction of the Engineer-in-Charge.
Thickness and grade of concrete: As specified in the item with graded stone aggregate of 10 mm
maximum size in proportion as per design criteria.

26.29.3 Testing: As per design mix criteria.
26.29.4 Measurement: Length and breadth of the application shall be measured correct to a cm
and area worked out to in sqm upto 2 decimal places, separately for different thicknesses specified
in the item.
26.29.5 Rates
Rates shall include all the materials, labour, T&P and full curing period in all the operations as
described above.
26.30 PROVIDING AND INJECTING GROUT

26.30.1 MATERIAl : The materials for injection grouting shall be approved by the Engineer-in-
charge.
26.30.2 Surface preparation

The final chipped off concrete surface and exposed reinforcement, if any, of the affected structural
member should be cleaned off all loose and foreign materials by free air blast and then with water
and allow it to dry. For the honey combed portion of the concrete or cracked concrete, drill holes at
least 18 mm in diameter and depth upto 50 mm or half the member thickness whichever is less, at the
required spacing, as directed by the Engineer-in-Charge. For cracked surface, open up cracks by
making V notch or groove of size 12 mm X 12 mm as directed by the Engineer-in-Charge. Remove
coarse debris and dust in opened up cracks and drilled holes by blowing air with hand operated blow
out pump. Concrete surface required to be grouted shall be free from all loose and unsound material.
The prepared surface should be clear of dust which could obstruct free flow of grout material and
also impede its bonding with concrete surface. Saturate the concrete in vicinity of crack / honey
combed concrete surface with water (but without excess water) only if the cement / polymer admixed
grout is to be injected.
26.30.3 Application: The emulsified acrylic polymer/SBR polymer shall be as specified and shall
conform to Manufacturer’s specification. The physical and mechanical properties of polymers shall
conform to manufacturer’s specification. One test shall be carried out mandatory for every lot of
acrylic polymer/SBR polymer supplied at site, before use in the work. The grouting equipment
shall be capable of supplying mixing, stirring and pumping grout to the satisfaction of Engineer-in-
charge. It shall have capacity to inject grout at a pressure upto 7 kg / sq. cm measured at grout
connections. It shall be capable of mixing and pumping the cement sand grout 1:2(1 cement : 2
sand) with water cement ratio ranging from 0.5 to 1.0. Wherever epoxy is to be used, the surface
of the concrete shall be dried with air blast, before grouting or applying epoxy. The cement grout in
proportion as directed by the Engineer-in-Charge shall be prepared. It should be lump free of
creamy consistency, thoroughly blended and shall be continuously stirred to keep the cement
particles in suspension to retain uniform consistency till grout is injected. In case of vertical cracks
the injection shall be started at the lowest nipple and continued until the injected grout begins to
flow out at the next higher nipple. The first nipple shall then be closed and injection continued
from second until grout flows out at the third and so on. The process shall be repeated until the
whole surface is treated. As soon as the system is cured, the nipples shall be suitably cut. In case
of honey combed concrete, each grout hole shall be grouted individually. The sequence of injection
shall be as per the directions of the Engineer-in-Charge.

26.30.4 Measurement : The measurement of grout material shall be on the basis of actual weight
of approved grout injected. Pre measurements of the quantities of such grouting materials brought
at site and balance quantities remaining at the end of grouting application shall be recorded
separately, which will determine the quantity of grout material actually injected. Adequate care is to
be taken by the contractor as not to waste the grout. The quantity which can be consumed immediately
within the prescribed time only shall be prepared in batches. The quantity of grout material wasted,
discarded, hardened shall not qualify for payment and shall be recorded for deduction at the end of
each operation.
26.30.5 Rates: The rate shall include all the operation, labour, materials described above except
injection nipple which will be paid in the relevant item.
26.31 PROTECTIVE FABRIC SCREENS

26.31.1 Material : The PVC woven cloth shall be approved by Engineer-in-charge.
26.31.2 Procurement & Execution :

Before execution, profile of protective fabric screen shall be got approved by the Engineer-in-charge.
Protective Fabric screening shall be provided by the contractor with PVC woven cloth covering full
height of the structure. It shall be provided by properly stitching the screen, having adequate lapping
on sides to prevent any rubbish from falling outside while demolishing, dismantling, gunniting, plastering
etc. and to protect passers -by from the falling debris. Screen material shall be fixed by suitable
means to the frames of scaffolding etc, and it is to be ensured that sagging of screen does not hinder
the repair process. The contractor shall maintain the protective screen in acceptable working conditions
for the entire duration of the repair work as required by the Engineer-in-Charge. All the windows,
ventilators, RCC jalis and openings shall be suitably covered and protected, in advance so as not to
cause any damage while doing the repair work. If any damage is caused or glass panes are broken,
these shall be made good by the contractor at his own cost and to the entire satisfaction of Engineer-
in-Charge.
26.31.3 Measurement: Length and height of the Protective fabric screen along the approved
profile shall be measured correctly and area worked out to in sqm upto 2 decimal places,
26.31.4 Rates; Rates shall include all the materials, labour, T&P in all the operations as described
above i/c cost of double scaffolding for fixing the protective screen.
26.32 CLEANING OF EXPOSED CONCRETE SURFACE BY SAND BLASTING.

26.32.1 Equipment: Sand blasting equipment and air compressor shall be got approved by
Engineer-in-Charge and should be capable of doing at least 14 sqm of cleaning the surface a day.
The coarse sand used in blasting shall be of zone III.
26.32.2 Operation: The cleaning should start after program for Shotcreting/Guniting, etc. is fixed,
such that cleaned, surface shall not be left alone for long. Cleaned surface should also be got
approved by Engineer –in-Charge. Proper care to the workers and environment should be taken
and other parts of the bldg should be protected to avoid any mishap.

26.32.3 Procedure – As described in the item.
26.32.4 Measurement- Length & breadth shall be measured correct to a cm and area worked out
to be sqm. upto 2 places of decimals.
26.32.5 Rates- Rate shall include all the operations as described above and in the item.
26.33 SHOTCRETING
26.33.1 Materials
Design mix of specified grade shall be got approved by Engineer-in-Charge before start of work.
The maximum size of graded stone aggregate shall not exceed 10mm. The minimum cement content
shall be as specified in the item.
26.33.2 Surface preparation- The surface shall be thoroughly cleaned and the cleaned surface
should be got approved by Engineer-in-Charge
26.33.3 Equipment- The compressor, gun, rubber pipes & other accessories shall be approved by
Engineer-in-Charge. The equipment should be capable of doing at least 40m2 of shotcreting a day
for 25mm thickness
26.33.4 Application – Application should start from top to bottom vertically and then from left to
right or right to left as per feasibility horizontally. The thickness shall be as spciefied in the item. Then
the surface shall be kept wet for at least 14 days or as per direction of Engineer-in-Charge. Thereafter
the surface shall be evaluated by sounding/tapping with a blunt metal instrument. If any hollow or
defective portion is observed, the same shall be redone after dismantling the same.
26.33.5 Testing: C.C cube strength should confirm the specified grade of concrete.
26.33.6 Measurement- The length and breadth shall be measured correct to a cm for different
thicknesses separately and area shall be worked out in m2 upto 2 decimal places.
26.33.7 Rates- Rate shall include all materials, labour, operations described above. The rate shall
also include for providing necessary ground wires etc. The leveling gauges if used shall be paid
separately. Payment under this item shall be made only after proper wet curing has been done and
surface has been satisfactorily evaluated.
26.34 PROVIDING AND INSERTING GALVANIZED STEEL INJECTION NIPPLE

26.34.1 Materials
Galvanized Steel injection nipple 12mm dia 75mm long shall be got approved by Engineer-in-
Charge. The chemical adhesive shall be got approved by the Engineer-in-Charge.
26.34.2 Surface preparation and operation: Holes shall be drilled in honey comb area and along
crack line of required dia (20mm to 30 mm) upto depth from 30mm to 80mm at required spacing.
Spacing and pattern of the holes shall be got approved by Engineer-in-Charge. The holes and cracks
shall be made dust free by blowing compressed air. After inserting the injection nipple, the holes shall
be sealed with chemical adhesive. The chemical adhesive shall be allowed to cure completely.

26.34.3 Measurement – Injection nipples shall be enumerated.
26.34.4 Rates- The rate shall include all the materials, labour, operations as described above.
26.35 PROVIDING & FIXING HARD DRAWN STEEL WIRE FABRIC

26.35.1 Materials- Hard drawn steel wire fabric of size 75 x 25 mm weighing not less than 7.75 kg/m2 or
any other suitable size wire mesh shall be got approved by Engineer-in-Charge before use on work. 10 mm
dia mild steel bar for shear key shall be approved by Engineer-in-Charge before use on work.
26.35.2 Preparation and procedure- The surface should be cleaned thoroughly before fixing of the mesh.
100mm long pieces of mild steel 10mm dia bar shall be cut. Each piece shall be bent into L shape. One arm
of the L shape piece shall be welded to existing reinforcement with the spacing 50cm center to center or less
in both directions as approved by Engineer-in-Charge. Then hard drawn steel wire fabric shall be inserted into
the shear keys and fastened with the help of binding wire or welded to shear keys as approved by Engineer-
in-Charge
26.35.3 Measurement – Length & breadth/height shall be measured correct to a cm and area shall be
worked out in sqm upto 2 decimal places.
26.35.4 Rates- Rates shall include all the materials labour and operations as described above.
26.36 LIGHT GAUGE STEEL FRAMED STRUCTURE (LGSFS)

26.36.1 General
Light Gauge Steel Framed Structure (LGSFS) is based on factory made galvanized light gauge steel
components produced by the cold forming method assembled as panels at site forming structural steel
framework of a building and varying wall and floor construction. The panels are assembled on site with screws
and bolts to form the internal and separating walls and inner leaf of the external walls of a building and floors
& ceiling.
The system can incorporate all types of architectural features like coving, boxes, cantilevers, projections,
infill walls, mezzanine floors etc. This system can also incorporate all types of services viz. electrical, gas and
plumbing etc. The design and engineering of the structures is executed by following the norms & guidelines
stipulated in relevant Indian Standards.
The system shall be used as framed steel structure.
26.36.2 Limitation of Use

(i) LGSFS may be used only upto G+3 level without any composition.
(ii) LGSFS may be used in G+3 and above with composition of hot rolled structures.
(iii) LGSFS shall not be used for buildings with vibrations.
(iv) Advisable span for LGSFS buildings shall be up to 6.5m.
26.36.3 Profiles and Sizes of Framing Components

The wall and floor panels are assembled from C section having minimum web depth 89 mm x 39 mm flange x
11 mm lip in required length as per structural design. The minimum thickness of section shall be 0.75 mm and
it shall be governed by the structural design requirement. The slots will be along centre line of webs and shall
be spaced minimum 250mm away from both ends of the member.
The steel sheet shall be galvanized (AZ-150gms Aluminium Zinc Alloy coated steel having minimum yield
strength 300-550 Mpa) conforming to AISI specifications and IBC 2009 for cold formed steel framing and
construction and also as per IS: 875-1987, ISO 800-1984 and IS:801- 1975.

26.36.4 Design and Stability Report
LGSFS frame shall be designed as per IS: 801 using commercially available software such as
Frame CAD Pro-11.7/ STAAD PRO-V8i/ArchitekV2.5.16/ Rivet architecture-2011 or equivalent. The
wind load shall be as per provisions of IS 875 (part -III).
The item also includes the submission of stability reports duly examined and issued by any
NIT/IIT.
26.36.5 Connections
The frame can be supplied in panellized or knock down condition in specific dimensions and
fastened with screws extending through the steel beyond by minimum of three exposed threads. All
self drilling tapping screws for joining the members shall have a Type II coating in accordance with
ASTM B633(13) or equivalent corrosion protection of gauge 10 & 12, TPI 16 & 8 of length 20mm.
The frames shall be fixed to RCC slab or Tie beam over Neoprene rubber using self expanding
carbon steel anchor bolt of dia as per approved drawings. design subject to minimum 12mm diameter
and 121mm length conforming to AISI 304 and 316 at 500mm c/c with minimum embedment of 100mm
in RCC (RCC to be paid separately) and located not more than 300mm from corners or termination
of bottom tracks complete in all respects.
26.36.6 Measurement:
Only weight of Cold form light gauge Steel C-section of thickness 0.75mm i/c zinc coating/sliting
etc. shall be considered in Kg, excluding connection accessories such as screws, nuts, bolts etc.
26.36.7 Rate
The rate includes the concept design, detailed design, fabrication of sections, transportation,
installation and all required fixing arrangement at site as described above.RCC to be paid separately.
26.37 EXTERNAL WALL SYSTEM ON LIGHT GAUGE STEEL FRAME WORK WITH OUTER FACE
HAVING 6MM THICK FIBER CEMENT BOARD
26.37.1 For Cement Fibre Board
26.37.1.1 Nominal Length and Width

Flat fibre cement sheets shall be available in nominal lengths up to 3 000 mm and nominal widths up
to 1240 mm.
26.37.1.2 Min. Modulus of Rupture: For 6mm & 9mm :13MPA
26.37.1.3 Thickness: Flat fibre cement sheets shall be 6, 8, 9mm.
26.37.1.4 Tolerances on Dimensions: Tolerances on nominal dimensions shall be as follows:

(a) On length and width (indicated by d)
d < 1000 mm : ± 5mm
1000 mm < d < 1600 mm: ± 0.5 percent
d>1600 mm : ± 8mm
These tolerances do not apply to oversize sheets.
(b) On thickness, e :
e < 6mm: ± O.6mm
e > 6mm: ± 10percent
For sheets without texture on the exposed face, the maximum difference between extreme values of the
thickness measurements within one sheet shall not exceed 15 percent of the maximum measured value

26.37.1.5 Tolerances on Shape
Straightness of edges: The tolerance on the straightness of edges shall be 3 mm/m for the
relevant dimension (length or width) when measured in accordance with the method given
Squareness of edges: The tolerance on the squareness of sheets shall be 4 mm/m when measured
in accordance with the method given.
26.37.1.6 Acceptance Tests

The objective of an acceptance test is to establish whether a batch of products conforms to a
specification. The tests shall be performed on samples drawn either from continuous production or
from a consignment (see also 8). The acceptance test” shall be cariedout at the manufacturer’s
works on sheets and test specimens cut from sheets as delivered. The following acceptance tests
shall be carried out:
(a) Dimensional and geometrical characteristics (compulsory) ,
(b) Bending strength (compulsory) , and
(c) Apparent density (compulsory).
26.37.1.7 Method for testing: As per IS 14862 2000
26.37.2 For Gypsum Plaster Board

26.37.2.1 Material
Gypsum Plaster Board shall conform to IS 2095.
Gypsum plaster shall conform to IS 2547 (Part 1). Byproduct gypsum conforming to the
requirements of IS 12679 shall also be used for the preparation of plaster.
Requirements, tests, sampling, finishing etc of Gypsum Plaster Board shall be as per IS 2095.
26.37.2.2 Fixing
Fixing the outer face with moisture resistant/ fire resistant fibre cement board of 6mm and 9mm
thickness (High Pressure Steam cured) with necessary accessories & GI self drilling/ tapping screws
etc., of required size(Screws shall be of counter sunk rib head of 1.60mm to 4 mm thick of 8 to 10
gauge of length varying from 25 to 45 mm) @ 60cm c/c, and a grove of 2-3mm shall be maintained
and filled with suitable arrangement as per approval of Engineer-in-charge.
Filling the groove (i.e. 2-3mm gap between boards),taping and jointing of the first layer 6mm and
9mm thick fiber cement boards with epoxy based sealing compound or with silicon sealant. Second
layer is fixed over it in a staggered pattern.
Fixing the internal face with 12.5mm thick gypsum plaster board fixed on 8mm thick fiber cement
board with self-drilling / taping screws / fasteners @ 60cm c/c of approved make, proper taping and
jointing to be done using fiber mesh tape and epoxy and acrylic based jointing compound for seamless
finish.
Fill the groove (i.e. 2-3mm gap between boards),taping and jointing 8mm thick fiber cement
board and 12.5mm thick gypsum plaster boards with epoxy based sealing compound, Acrylic based
sealing compound, Non woven reinforcement Tape as per direction of Engineer in charge.(Use a
flexible knife so that no air bubble is entrapped. Allow 1-2 hours gap. Once hard tacky or set, apply
a coat of Acrylic based sealing compound paste to flash fill the beveled area. After 2-4 hours go on
to repeat a skin coat with Acrylic based sealing compound to securely embed the 40mm width (non

woven reinforcement Tape. Use only flexible steel knife, such as provided with packs, to avoid air
entrapment within compound. After overnight drying shrinkage apply a coat of acrylic based sealing
compound to compensate shrinkage. Finally cover the bevel portion with any suitable overall skin
coat with a desired full surface-leveler material).
26.37.2.3 Measurement:
The length and breadth of fibre cement board shall be measured in any one face, correct to the
nearest cm and area worked out in square metres correct to two places of decimal.
26.37.2.4 Rate:
above. Nothing extra shall be paid for fixing arrangement i.e. drilling, nut & bolts, filling groove etc.(cost
of frame work to be paid for separately).
26.38 INTERNAL WALL PANELS ON LIGHT GAUGE STEEL FRAME WORK WITH 12.5MM THICK
GYPSUM PLASTER BOARD
26.38.1 For Cement Fibre Board
26.38.1.1 Nominal Length and Width

Flat fibre cement sheets shall be available in nominal lengths up to 3 000 mm and nominal widths
up to 1240 mm.
26.38.1.2 Min. Modulus of Rupture: For 8 mm :10 MPA
26.38.1.3 Thickness: Flat fibre cement sheets shall be 8 mm.
26.38.1.4 Tolerances on Dimensions: Tolerances on nominal dimensions shall be as follows:

(a) On length and width (indicated by d)
d < 1000 mm : ±5mm
1000 mm < d < 1600 mm: ± 0.5 percent
d > 1600 mm : ±8mm
These tolerances do not apply to oversize sheets.
(c) On thickness, e :
e < 6mm: ± 0.6mm
e > 6mm: ± 10percent
For sheets without texture on the exposed face, the maximum difference between extreme values
of the thickness measurements within one sheet shall not exceed 15 percent of the maximum measured
value
26.38.1.5 Tolerances on Shape

Straightness of edges: The tolerance on the straightness of edges shall be 3 mm/m for the
relevant dimension (length or width) when measured in accordance with the method given Squareness
of edges: The tolerance on the squareness of sheets shall be 4 mm/m when measured in accordance
with the method given.
26.38.1.6 Acceptance Tests

The objective of an acceptance test is to establish whether a batch of products conforms to a
specification. The tests shall be performed on samples drawn either from continuous production or

from a consignment (see also 8). The acceptance test shall he carried out at the manufacturer’s
works on sheets and test specimens cut from sheets as delivered. The following acceptance tests
shall be carried out:
(a) Dimensional and geometrical characteristics (compulsory) ,
(b) Bending strength (compulsory) , and
(c) Apparent density (compulsory).
26.38.1.7 Method For Testing

As per IS 14862 2000
26.38.2 For Gypsum Plaster Board
26.38.2.1 Gypsum Plaster Board

Gypsum Plaster Board shall conform to IS 2095.
Gypsum plaster shall conform to IS 2547 (Part 1). Byproduct gypsum conforming to the
requirements of IS 12679 shall also be used for the preparation of plaster.
Requirements, tests, sampling, finishing etc of Gypsum Plaster Board shall be as per IS 2095.
26.38.2.2 Fixing
Fixing the 12.5mm thick gypsum plaster board on 8mm thick fiber cement board with self-drilling
/ taping screws / fasteners @ 60cm c/c of approved make, Screws shall be of counter sunk rib head
of 1.60mm to 4 mm thick of 8 to 10 gauge of length varying from 25 to 45 mm. Proper taping and
jointing to be done using fiber mesh tape and epoxy and acrylic based jointing compound for seamless
finish.
Fill the groove (i.e. 2-3mm gap between boards),taping and jointing 8mm thick fiber cement
board and 12.5mm thick gypsum plaster boards with epoxy based sealing compound, Acrylic based
sealing compound, Non woven reinforcement Tape as per direction of Engineer in charge.(Use a
flexible knife so that no air bubble is entrapped. Allow 1-2 hours gap. Once hard tacky or set, apply
a coat of Acrylic based sealing compound paste to flash fill the beveled area. After 2-4 hours go on
to repeat a skin coat with Acrylic based sealing compound to securely embed the 40mm width (non
woven reinforcement Tape. Use only flexible steel knife, such as provided with packs, to avoid air
entrapment within compound. After overnight drying shrinkage apply a coat of acrylic based sealing
compound to compensate shrinkage. Finally cover the bevel portion with any suitable overall skin
coat with a desired full surface-leveler material).
26.38.2.3 Measurement:
The length and breadth of fibre cement board shall be measured on one face,correct to the
nearest cm and area worked out in square metres correct to two places of decimal.
26.38.2.4 Rate:
above. Nothing extra shall be paid for fixing arrangement i.e. drilling, nut & bolts, filling groove etc.
26.39 EXTERIOR FACE PANELS BREATHABLE VAPOUR BARRIER UNDERNEATH THE CEMENT
FIBER BOARD
26.39.1 General
Vapour diffusion will occur through exterior face panels where there is difference of vapour
pressure between interior and exterior of the building. Vapour flows from high vapor pressure to low
vapor pressure area.

In colder climates, cold outdoor contains little moisture and moisture it does contain will be at low
Pressure, so net vapor flow is generally inside to outside. In warmer climates the reverse is true, so
the net vapour flow is from outside to inside of building. Therefore, in warmer climates, exterior
elements are typically more resistant to vapor flow. So the breathable vapor barrier shall be fixed on
the exterior face of panels.
It shall be used to control water vapor diffusion through the wall. It Building exterior require this,
so that water condensation is minimized within wall assemblies otherwise Condensation can lead to
deterioration of the structure and mold growth.
26.39.2
Some common vapour barriers include polyethylene, aluminium foil, some rubber membranes,
and polyurethane coatings.
The material shall be chos en on the basis of the property called “permeance”. It is the maximum
rate of water vapour that can pass through a vapour barrier. As per NBCC (National Building code of
Canada), the maximum permeance shall be 1 perm ( 60 Nano gram per second per square meter per
pascal)
The length and breadth of vapour barrier shall be measured on one face, correct to the nearest
cm and area worked out in square metres correct to two places of decimal.
26.39.4 Rate:
above. Nothing extra shall be paid for fixing arrangement.
26.40 MOISTURE RESISTANT/FIRE RESISTANT 6 MM THICK FIBER CEMENT BOARD

26.40.1 The specification for fibre cement board shall be as per 26.37.1.
26.40.2 Fixing
Fixing the moisture resistant/ fir resistant 6mm thick fibre cement board (High Pressure Steam
cured) with necessary accessories & GI self drilling/ tapping screws etc., of required size(Screws
shall be of counter sunk rib head of 1.60mm to 4 mm thick of 8 to 10 gauge of length varying from 25
to 45 mm), and filling the groove (i.e. 2-3mm gap between boards),taping and jointing of the first
layer 6mm and 9mm thick fiber cement boards with epoxy based sealing compound or with silicon
sealant. Second layer is fixed over it in a staggered pattern, with suitable arrangement as per approval
of Engineer-in-charge.
The length and breadth of fibre cement board shall be measured correct to the nearest cm and
area worked out in square metres correct to two places of decimal.
26.40.4 Rate:
above. Nothing extra shall be paid for fixing arrangement i.e. drilling, nut & bolts, filling groove etc.
26.41 GLASS FIBRE REINFORCED GYPSUM (GFRG) PANEL

26.41.1 Materials:

26.41.1.1 GFRG panel
Glass Fiber Reinforced Gypsum is a building panel made-up of calcined gypsum plaster, reinforced
with glass fibers.
Grade and Type:

Class 1- Water Resistant grade – Panels that shall be used for external walls, in wet areas and/
or as floor and wall formwork for concrete filling.
Class 2 – General grade - panels that shall be used structurally or non-structurally in dry areas.
These panels are generally unsuitable for use as wall or floor formwork.
Class 3 – Partition grade – panels that may only be used as non- structural internal partition
walls in dry areas only.
Dimension
Typical Dimension of GFRG building panel is 12.0m x 3.0m x 0.124m. Each 1.0m segment of the
panel contains four cells. Each cell is 250mm wide and 124mm thick containing a cavity of 230 mm x
94 mm. The various cells shall be interconnected by solid ‘ribs’ (20 mm thick) and ‘flanges’ (15 mm
thick), comprising gypsum plaster, reinforced with 300 - 350 mm glass fiber roving, located randomly
but centrally. The weight of panel shall be 40kg / sqm and density is 1140 kg/m2.
26.41.1.2 Infill:
M25 concrete at initial 50mm thickness and thereafter with quarry dust mixed with 5% cement (by
volume) in three stages each after 90 minute interval.
26.41.1.3 Weld mesh:

10 gauge weld mesh of size 100mm x 100 mm for floor/roof slab concrete screed over the micro
beams as reinforcement.
26.41.1.4 Joint sealant:

Joint filling sealant compound with grout RW/or equivalent.
26.41.1.5 Water Proofing:

Water proofing of vertical joints between door/windows/ventilators frames by Zycosil/equivalent &
Zycoprime/equivalent solution.
26.41.2 Construction Procedure

26.41.2.1 GFRG Panel
As per the building plan and design, each wall panel shall be cut at the factory using an automated
cutting saw. Door/window/ventilator and openings for AC unit etc. shall also be cut and panels for
every floor marked as per the building drawing. Panels are vertically loaded at the factory on stillages
for transportation to the construction site on trucks. Panels shall be erected over the RCC plinth
beam and concrete is infilled from top. All the panels shall be erected as per the building plan by
following the notation.
26.41.2.2 Erection:
Each panel shall be erected level and plumb and shall be supported by lateral props to keep the
panel in level, plumb and secure in position. Embedded RCC lintels shall be provided wherever
required by cutting open external flange. Reinforcement for lintels and RCC sunshades shall be
provided with required shuttering and support. All GFRG wall panels at the ground floor are to be
erected over a network of RC plinth beams supported on suitable foundation. For providing embedded
micro beams, top flange of the respective cavity is cut and removed in such a way that minimum 25

mm flange on both end is protruded . RC concrete screed of minimum 50 mm thickness is provided
above the GFRG floor panel, which is reinforced with weld mesh of minimum size of 10 gauge 100
mm × 100 mm. This RC screed and micro beam act together as series of embedded T beams. The
thickness of the RC screed, reinforcement and interval of embedded RC micro beams depends on
the span and intensity of imposed load. The connectivity between the horizontal tie beam, embedded
RC micro beams, concrete screed and vertical rods in GFRG wall, and ensures perfect connection
between floor/roof slab and walling system.
The procedure of Erection of panel shall be as follow:

1) Align the wall by marking with chalk line, where wall is to be erected.
2) Then fix the hold fast (regular door frame hold fast of 150mm) by plumbing wall. Two nos. of
hold fasts are required for each panel.
3) Simultaneously cut the pocket of electrical points & electrical conduits to be inserted inside
cavity of Rapid wall.
4) Then erect the panel by supporting with props.
5) Fix electrical switch boxes.
6) Fix other panels same as per the above method up to required length
7) Check the plumb & line of the wall.
8) Fill the holdfast gap with concrete.
9) Finish the joints of two panels by fixing fiber tape with stucco as follow:
(i) Make a slot of 8mm wide & 2mm deep at the joint of panel.
(ii) Fix the jointing fiber tape and finish the surface with stucco.
10) Joints of panel with RCC column/ beam shall be finished by stucco with reinforcing fiber of
used cement bags.
11) Finish the gap around electrical points and between panel & slab/beam by stucco.
26.41.2.3 Reinforcement:
Reinforcement for micro-beams shall be placed and weld mesh as reinforcement is placed.
Concrete is poured for micro-beams and RCC slab. These should results in the embedded RCC
micro beams and 50 mm thickness screed concrete become a series of “T” beams. Erection of wall
panel and floor slab for upper floor can be arranged the following day. Vertical reinforcement of floor
below is provided with extra length so as to protrude to 0.45 m to serve as start up rods and lap
length for upper floor. Once the wall panels are erected on the upper floor, vertical reinforcement
rods are provided, door/window frames fixed and RCC lintel cast.
26.41.2.4 Concrete infill:

After inserting vertical steel reinforcement as per the structural design and clamps for wall corners
are in place to keep the wall panels in perfect position, concrete having 12mm aggregate shall be
poured from the top into the cavities using a small hose to go down at least 1.5 to 2 m into the cavities
for directly pumping the concrete from ready mixed concrete truck. For small building construction,
concrete can be poured manually using a funnel. Filling the panels with concrete shall be done in
three layers of 1m height with an interval of 90 minute between each layer. There is no need to use
vibrator because gravitational pressure acts to self compact the concrete inside the water tight
cavities.

26.41.2.5 Embedded RCC tie beam all around at each floor/roof slab level:
An embedded RCC tie beam to floor slab is to be provided at each floor slab level, as an essential
requirement of national building code against earth quakes. For this, web portion to required beam
depth at top shall be cut and removed for placing horizontal reinforcement with stirrups and concreted.
GFRC panel for floor/ roof slab in combination with RCC for floor/roof slab shall also be cut to
required size and marked with notation. First the wall joints and other cavities and horizontal RCC tie
beams are infilled with concrete; then wooden plank of 0.3 to 0.45 m wide is provided to room span
between the walls with support wherever embedded micro beams are there; finally roof panels shall
be lifted by crane using strong sling tied at mid-diagonal point, so that panel will float perfectly
horizontal. Each roof panel is placed over the wall in such a way that there shall be at least a gap of
40 mm. This is to enable vertical rods to be placed continuously from floor to floor and provide
monolithic RCC frame within GFRC panel. Wherever embedded micro-beams are there, top flanges
of roof panel are cut leaving at least 25mm projection.
26.41.2.6 GFRG panel for floor/roof slab in combination with RCC

GFRG panel for floor/roof slab shall be cut to required size and marked with notation. First, wall
joints, other cavities and horizontal RCC tie beams are in-filled with concrete; then wooden plank 0.3
to 0.45m wide shall be provided to room span between the walls with support wherever embedded
micro beams are there and then roof panels shall be lifted by crane. Each roof panel shall be placed
over the wall in such a way that there will be a gap of at least 40mm. This is to enable vertical rods to
be placed continuously from floor to floor and provide monolithic RCC frame within GFRG panel.
Wherever embedded micro-beams are there, top flanges of roof panel shall be cut leaving at least
25mm projection. Reinforcement and weld mesh is placed for micro beams and then concrete shall
be poured for micro beams and RCC slab.
26.41.2.7 Erection of wall panel and floor slab for upper floor
Vertical reinforcement of floor below shall be provided with extra length so as to protrude to
0.45m to serve as start up rods and lap length for upper floor. Once the wall panels are erected on
the upper floor, vertical reinforcement rods, door/window frames fixed and RCC lintels shall be casted.
Then concrete where required and joints shall be filled. Thereafter, RCC tie beams all around shall
be concreted.
26.41.2.8 Waterproofing:
Water proofing treatment of Vertical joints (of external side and internal side) between door
frame, window & ventilator frames (on all four sides) of outer wall over the Zycosil/equivalent &
Zycoprime/equivalent solution already applied(before the installation of door / window / ventilator
frames in position) and fine finish with Grout RW/equivalent. Water proofing treatment of RCC sunshade
with Zycosil/equivalent water proofing Solution (1 litre of Zycosil/equivalent& 20 litres of water stirred
first & 2 litres of Zycoprime/equivalent added and stirred (total 23 litres)) till it meets the saturation
level and testing as per RILEM or by water drops test in which water drops do not absorb but drops
remain or rolls.
26.41.2.9 Sealing of joints :

In-filling / sealing of joint between RCC lintel cum sunshade and wall (on external side) in all
floors by pushing in Grout RW/equivalent in paste form and coving 20 mm x 20 mm after applying a
coat of Zycosil/equivalent & zycoprime/equivalent solution before cement plastering of top, bottom
and sides of RCC sunshade.
The Quality Assurance Plan for GFRG Panel mentioned in Table 26.9

Table 26.9
Material Testing
Quality Assurance Plan for GFRG Panel
S. No. Parameters to Requirement Specified Test Method As Frequency of

be inspected per BMBA Testing
PC-3:2011
A. Rapidwall/GFRG Panel
1. Visual Shall be free from defects like Clause10.4.1 Once in every ten
Appearance cracks, corrugations, ripples, panels
stains, pockmarks, loose corners
etc.
2. Overall Length & height shall be within Clause10.4.2 Once in every fifty
Dimensional tolerance limit of ±3mm & panels
Tolerances thickness +3mm to 0mm
3. External Skin Shall be ± 3mm (General /Water Clause10.4.2 Once in every fifty
thickness resistance grade) panels
tolerance Min 8mm Partition grade
4. Internal Rib Shall be ± 2mm (General /Water Clause10.4.2 Once in every fifty
thickness resistance grade) panels
tolerance Shall be ± 5mm (Partition grade)
5. Cavity Width & Shall be ± 3mm (General / Water Clause10.4.2 Once in every fifty
Depth Tolerance resistance grade) panels
Shall be ± 7mm (Partition grade)
6. Unevenness Shall be less than 1mm (Side A) Clause10.4.2 Once in every fifty
Shall be less than 3mm (Side B) panels
7. Panel weight Shall be 40 Kg/m² ± 6% (Class 1 Clause10.4.4 Once in every fifty

& 2) panels
shall be 40 Kg/mm²±15% (Class 3)
8. Water Content Shall be less than 1% (measured Clause 10.4.3 Once in every fifty
immediately after drying panels
process)
9. Water Shall be less than 5% by weight Clause 10.4.5 Once in every fifty
Absorption Rate (after 24 hrs of immersion in panels
water)
10. Vertical Load Shall be more than160 kN/m Clause 10.4.6 Once in every fifty
bearing capacity (General / Water resistance panels
(Compressive grade)
strength) Shall be more than 90 kN/m
(Partition grade)
11. Out of plane Shall be more than 2.1kN/m Clause 10.4.7/ Once in every fifty
Flexural capacity (General /Water resistance Clause 10.4.8 panels
(Flexural grade)
strength) Shall be more than1.3 kN/m
(Partition grade)
12. “ U” Value Shall be 2.85W/M² C IS3346:1980 Once in a year or

12. “ U” Value Shall be 2.85W/M² C IS3346:1980 Once in a year or
when the
13. Thermal Shall be 0.617 W/m C IS3346:1980 composition
Conductivity (K) changes and
initially at the time
14. Sound Shall be 40 (STC) ISO 140-3:1996 of approval
transmission
Average compressive strength Clause10.4.9 Once in a year or

Durability shall not be less than 7.52 when the
2
i. wetting & N/mm composition
drying Shall not suffer any apparent changes and
15. ii. Salt spray damage after 20 cycles initially at the time
0
Shall withstand 700-1000 C Clause10.4.10 of approval
after 4hr
16. Fire Resistance
B. Raw Materials
1. Calcined i.Shall be more than 90% as i. Once in a day
Gypsum Calcium Sulphate As per ii. Once in a shift
ii. Combined moisture shall not Company
be more than 6.2% Standard
2. Ammonium Shall not be less than 99.14% as As per Once on delivery at
Carbonate purity Company site
Standard
3. Glass Roving These raw materials are performance based. Test Certificates provided by
the manufacturers are verified at the time of delivery.
4. BS-94 M
5. Retarder D-50
All measurement of the area is to be measured correct to a centimeter. The area shall be calculated
in square meter correct to two decimal places. No deductions shall be made for making openings for
doors, windows, ventilators etc.
26.41.4 Rates :
The rates shall include the cost of all materials and labour involved in all the operations described
above.
26.41.5 Glossory:
Cavity : The internal hollow cores inside the panel are called the cavity .
Panel Length: The panel length is the maximum horizontal dimension of a single wall without
vertical joint.
Panel Thickness: The panel thickness is the distance between the external faces of the two
external skins.
Height :The panel height is the maximum vertical dimension of a single wall without a horizontal
joint.
A and B Side: The smoother side of the GFRG panel cast against the machine bed in the
manufacturing process is called the A side. The B side is screeded and is relatively rougher than A
side.

26.42 GALVANIZED STEEL DECK SHEET ROOFING COVERED WITH CONCRETE
26.42.1 Materials
26.42.1.1 Galvanized Steel Deck Sheet (Fig 26.14)
The base metal of plain galvanized sheets and coils shall conform to IS 1079 or IS 513 as the case may
be. However, deck sheet shall conform to IS 277:2003. When it is not possible to test the base metal before
galvanizing, the base metal may be tested after stripping off the zinc coating. The grade of coating shall be
minimum 275 g/sqm.
Galvalume and pre-painted galvalume sheets are not recommended for use in contact with concrete.
26.42.1.2 Shear Connectors (See Fig 26.15 A, 26.15B & 26.15C)

Shear connectors (Shear studs) at the interface of the concrete and sheet are provided. These shear
connectors are embossment in deck sheets as typical pattern unique to each profile.
To ensure friction at the embossments, there should not be any paint or grease on the sheet surface in
contact with concrete nor should any vibrating load be permitted to act on the slab until the concrete has set
completely.
The length after weld should extend at least 35mm above the top of the main rib of the deck profile. The
distance from the deck rib shall be minimum 25mm.
Single connector to be located at the center of beams except at butt joints where connectors to be
staggered.
To avoid damaging to decking, connectors to be located along the predetermined lines marked on it.
Minimum Spacing of the connectors shall be 5 times the diameter of shank and maximum shall not be
more than 600 or 4 times the depth of slab.
Connectors in pair to have a minimum gap of 4 times the diameter of shank.
26.42.1.3 Wire Mesh

3 mm wire mesh laid at 100x100 mm grid is to be provided to control the cracking.
26.42.1.4 Edge Trim

Galvanized edge trim is provided where requested around perimeter and void edges. This edge trim acts
as permanent formwork only to support the wet weight of concrete during construction.
26.42.2 Finish
The roof when completed shall be true to lines, and slopes and shall be leak proof.
The length and breadth shall be measured correct to a cm. Area shall be worked out in sqm correct to two
places of decimal.
The area of roof shall be measured on the flat without allowance for laps and corrugations. Roof with
curved sheets shall be measured and paid for separately. Measurements shall be taken on the flat and not
girthed.
No deduction in measurement shall be made for opening upto 0.4 sqm and nothing extra shall be allowed
for forming such openings. For any opening exceeding 0.4 sqm in area, deduction in measurements for the full
opening shall be made and in such cases the labour involved in making these openings shall be paid for
separately. Cutting across corrugation shall be measured on the flat and not girthed. No additions shall be
made for laps cut through.

26.42.4 Rate
described above including all shear connectors, wire mesh, edge trim, seal, scaffolding, machinery
for operations required etc. but excluding the cost of structural steel like beams, columns, joists etc.
and concrete of different grade as per design.
26.43 PRECAST CONCRETE SOLID BLOCK

26.43.1 Precast Concrete Solid Block Made of C & D Waste
The block shall be machine moulded and should be free from visible cracks, flaws warpage &
organic matter.
26.43.1.1 Dimensions
The nominal dimensions of block shall be as follows:
Length: 400 or 600mm
Height: 100mm
Width: 200mm.
Most commonly used size is 400 x 200 x 100mm.
26.43.1.2 Classification
Blocks shall have minimum compressive strength of 10N/mm² or 100kgf/cm.
The blocks shall have smooth rectangular faces with sharp corner and shall be uniform in colour.
26.43.1.3 Sampling and Tests

Samples of Blocks shall be subjected to the following tests:
(a) Block density
(b) Dimensional tolerance.
(c) Water absorption.
(d) Drying shrinkage
(e) Compressive strength.
26.43.1.3.1 Sampling: For carrying out compressive strength, water absorption, and dimensional
tests, the samples of blocks shall be taken at random according to the size of lot as given in Table A
below. The sample thus taken shall be stored in a dry place until tests are made. For the purpose of
sampling, the following definition shall apply.
(a) Lot: A collection of blocks of same class and size, manufactured under relatively similar
conditions of production. For the purpose of sampling a lot shall contain a maximum, of
10000 blocks.
In case a consignment has blocks more than 10000 of the same classification and size and
manufactured under relatively similar conditions of production, it shall be divided into lots
of 10000 Blocks or part thereof.
(b) Sample: A collection of blocks selected for inspection and/or testing from a lot to reach the
decision regarding the acceptance or rejection of the lot.
(c) Defective: A block failing to meet one or more of the specified requirements.

26.43.1.3.2 The samples shall be taken as below:
(i) Sampling from a Stack: When it is necessary to take a sample from a stack, the stack
shall be divided into a number of real or imaginary sections and the required number of
blocks drawn from each section. For this purpose blocks in the upper layers of the stack
shall be removed to enable units to be sampled from places within the stack.
Visual characteristics: The blocks shall be selected and inspected for ascertaining their
conformity to the requirements of the relevant specification. The number of blocks to be
selected from a lot shall depend on the size of lot and shall be in accordance of Table A for
visual characteristics in all cases and dimensional characteristics if specified for individual
blocks.
(ii) Visual Characteristics: All the blocks selected above in accordance with Table A shall be
examined for visual characteristics. If the number of defective blocks found in the sample is
less than or equal to the corresponding number as specified in of Table A the lot shall be
considered as satisfying the requirements of visual characteristics, otherwise the lot shall
be deemed as not having met the visual requirements.
(iii) Dimensional Characteristics: The number of blocks to be selected for inspecting the
dimensions and tolerance shall be in accordance with Table A. These blocks will be divided
into groups of 20 blocks at random and each of the group of 20 blocks thus formed will be
tested for all the dimensions and tolerances. A lot shall be considered having found meeting
the requirements of dimensions and tolerance if none of the groups of blocks inspected
fails to meet the specified requirements in table 26.10.
TABLE 26.10
No. of Sample No. of samples required to be tested from sample size

blocks in size
lot Dimensional Visual Blocks Compressive Water Drying
characteristics defects density strength absorption shrinkage
0-10000 20 20 20 3 8 3 3
(i) Scale of Sampling and Criteria for Physical Characteristics: The lot which has been
found satisfactory in respect of visual and dimensional requirements shall be next tested
for physical characteristics like block density compressive strength, water absorption, drying
shrinkage as specified in relevant material specification. The blocks for this purpose shall
be taken at random from those already selected above. The number of blocks to be selected
for each of these characteristics shall be in accordance with relevant columns of Table A.
26.43.1.3.3 Dimensional Tolerances: The variation in the length of the units shall not be more
than ± 5mm and variation in height and width of units, not more than ± 3mm.
The dimensions of blocks when tested as described above as per procedure described in Appendix
A of chapter 6 shall be within the following limits per 20 blocks or locally available size as approved by
Engineer-in-charge.
Length 8100 to 7900 mm (8000 ± 100 mm)
Width 4060 to 3940 mm (4000 ± 60 mm)
Height 2060 to 1940 mm (2000 ± 60 mm) for 100 mm high block.

26.43.1.3.4 Block Density: The average block density when tested in accordance with the procedure
laid down in IS 2585 Part 1-2005 shall not be less than 1800kg/m³.
26.43.1.3.5 Compressive Strength: The blocks, when tested in accordance with the procedure laid
down in IS 2185 (part-1) shall have a minimum average compressive strength of 10N/mm².
26.43.1.3.6 Water Absorption: The average water absorption of blocks when tested in accordance
with the procedure laid down in IS 2185 part 1- 2005 shall be not more than 10% by weight.
26.43.1.3.7 Drying Shrinkage: The average drying shrinkage of block when tested in accordance
with the procedure laid down in IS 2185 part 1- 2005 shall not be more than 0.1%
26.43.2 Block Work

26.43.2.1 Mortar
The mortar for the C&D waste block work shall be as specified, and conform to accepted standards.
Lime shall not be used where reinforcement is provided in block work.
26.43.2.2 Soaking of Blocks

Blocks shall be soaked in water before use for a period for the water to just penetrate the
whole depth of the blocks. Alternatively blocks may be adequately soaked in stacks by profusely
spraying with clean water at regular intervals for a period not less than six hours. When the blocks
are soaked they shall be removed from the tank sufficiently early so that at the time of laying they
are skin-dry. Such soaked blocks shall be stacked on a clean place where they are not again
spoiled by dirt earth etc.
Note I:The period of soaking may be easily found at site by a field test in which the blocks are
soaked in water for different periods and then broken to find the extent of water penetration. The
least period that corresponds to complete soaking will be the one to be allowed for in construction
work.
Note II: If the blocks are soaked for the required time in water that is frequently changed the soluble
salt in the blocks will be leached out, and subsequently efflorescence will be reduced.
26.43.2.3 Laying
26.43.2.3.1 Blocks shall be laid in single Block masonry, blocks shall be laid in stretcher bond. Half or
cut blocks shall not be used except as closer where necessary to complete the bond. Closers in such
cases, shall be cut to the required size and used near the ends of the wall.
Block work for wall thickness 200mm shall be done with block laid flat with its height (100mm)
vertical. It shall be done with cement mortar 1:6 (1 cement: 6 coarse sand) Block work for wall
thickness 100mm shall be done with the same block laid such that its height of 100mm being horizontal.
It shall be done with cement mortar 1:4 (1cement: 4 coarse sand).
26.43.2.3.2 All loose materials, dirt and set lumps of mortar which may be lying over the surface on
which block work is to be freshly started, shall be removed with a wire brush and surface wetted.
Blocks shall be laid on a full bed of mortar, when laying, each block shall, be properly bedded and set
in position by gently pressing with the handle of a trowel. Its inside face shall be buttered with mortar
before the next block is laid and pressed against it. Joints shall be fully filled and packed with mortar
such that no hollow space are left inside the joints.
26.43.2.3.3 The walls shall be taken up truly in plumb or true to the required batter where specified.
All courses shall be laid truly horizontal and all vertical joints shall be truly vertical. Vertical joints in

the alternate course shall come directly one over the other. Quoin, Jambs and other angles shall be
properly plumbed as the work proceeds. Care shall be taken to keep the perpends properly aligned
within following maximum permissible tolerances :
(a) Deviation from vertical within a storey shall not exceed 6 mm per 3 m height.
(b) Deviation in verticality in total height of any wall of building more than one storey in height
shall not exceed 12.5 mm.
(c) Deviation from position shown on plan of any block work shall not exceed 12.5 mm.
(d) Relative displacement between load bearing wall in adjacent storeys intended to be vertical
alignments shall not exceed 6 mm.
(e) A set of tools comprising of wooden straight edge, masonic spirit levels, square, 1 metre
rule line and plumb shall be kept on the site of work for every 3 masons for proper check
during the progress of work.
26.43.2.3.4 All quoins shall be accurately constructed and the height of block courses shall be kept
uniform. This will be checked using graduated wooden straight edge or storey rod indicating height
of each course including thickness of joints. The position of damp proof course, window sills, bottom
of lintels, top of the wall etc. along the height of the wall shall be marked on the graduated straight
edge or storey rod. Acute and obtuse quoins shall be bonded, where practicable in the same way as
square quoins. Obtuse quoins shall be formed with squint showing three quarters block on one face
and quarter block on the other.
26.43.2.3.5 The block work shall be built in uniform layers.

No part of the wall during its construction shall rise more than one metre above the general
construction level. Parts of wall left at different levels shall be raked back at an angle of 45 degrees
or less with the horizontal. Toothing shall not be permitted as an alternative to raking back. For
100mm block partition to be keyed into main walls, indents shall be left in the main walls.
26.43.2.3.6 All pipe fittings and specials, spouts, hold fasts and other fixtures which are required to
be built into the walls shall be embedded, as specified, in their correct position as the work proceeds
unless otherwise directed by the Engineer-in-Charge.
26.43.2.3.7 To facilitate taking service lines later without excessive cutting of completed work, sleeves
(to be paid separately) shall be provided, where specified, while raising the block work. Such sleeves
in external walls shall be sloped down outward so as to avoid passage of water inside.
26.43.2.3.8 Top of the block work in coping and sills in external walls shall be slightly tilted. Where
block coping and sills are projecting beyond the face of the wall, drip course/throating (to be paid
separately) shall be provided where indicated.
26.43.2.3.9 Care shall be taken during construction that edges of jambs, sills and projections are not
damaged in case of rain. New built work shall be covered with gunny bags or tarpoulin so as to
prevent the mortar from being washed away. Damage, if any, shall be made good to the satisfaction
of the Engineer-in-Charge.
26.43.2.3.10 Horizontal reinforcement in the form of MS bars, 2 Nos, 6 mm dia each shall be provided
at every alternate third coarse for block masonary of wall thickness 100mm.

26.43.2.3.11 In retaining walls and the like, where water is likely to accumulate, weep holes, 50 to 75
mm square shall be provided at 2 m vertically and horizontally unless otherwise specified. The lowest
weep hole shall be at about 30 cm above the ground level. All weep holes shall be surrounded by
loose stones and shall have sufficient fall to drain out the water quickly.
Note : Work of providing loose stone will be payable extra.
26.43.2.4 Joints
Specified thickness of joints shall be of 1 cm.
26.43.2.4.1 Finishing of Joints: The face of block work may be finished flush or by pointing. In flush
finishing either the face joints of the mortar shall be worked out while still green to give a finished
surface flush with the face of the block work or the joints shall be squarely raked out to a depth of 1
cm while the mortar is still green for subsequently plastering. The faces of block work shall be cleaned
with wire brush so as to remove any splashes of mortar during the course of raising the block work.
In pointing, the joints shall be squarely raked out to a depth of 1.5 cm while the mortar is still green
and raked joints shall be brushed to remove dust and loose particles and well wetted, and shall be
later refilled with mortar to give ruled finish. Some such finishes are ‘flush’, ‘weathered’, ruled, etc.
26.43.2.5 Curing
The block work shall be constantly kept moist on all faces for a minimum period of seven days.
Block work done during the day shall be suitably marked indicating the date on which the work is
done so as to keep a watch on the curing period.
26.43.2.6 Scaffolding
Shall be as specified in clause 6.2.7.
26.43.2.7 Measurements
26.43.2.7.1 Block work with 200mm wall thickness shall be measured in cubic metres unless otherwise
specified. Any extra work over the specified dimensions shall be ignored. Dimensions shall be measured
correct to the nearest 0.01 m i.e. 1 cm. Areas shall be calculated to the nearest 0.01 sqm. and the
cubic contents shall be worked out to the nearest 0.01 cubic metres.
26.43.2.7.2 Block work shall be measured separately in the following stages:

(a) From foundation to floor one level (Plinth level)
(b) Plinth (floor one) level to floor two level
(c) Between two specified floor levels above floor two level
Note : (i) Block work in parapet walls, mumty, lift machine room and water tanks constructed on the
roof upto 1.2 m height above roof shall be measured together with the corresponding work of the
floor next below.
26.43.2.7.3 No deductions or additions shall be done and no extra payment made for the following :
Note : Where minimum area is defined for deduction of an opening, void or both, such areas shall
refer only to opening or void within the space measured.
(a) Ends of dissimilar materials (that is, joists, beams, lintels, posts, girders, rafters, purlins,
trusses, corbels, steps, etc.); up to 0.1 m2 in section;
(b) Opening up to 0.1 m2 in area (see Note);

(c) Wall plates, bed plates, and bearing of slabs, chajjas and the like, where thickness does
not exceed 10 cm and bearing does not extend over the full thickness of wall;
(d) Cement concrete blocks as for hold fasts and holding down bolts;
(e) Iron fixtures, such as wall ties, pipes upto 300 mm diameter and hold fasts for doors and
windows; and
(f) Chases of section not exceeding 50 cm in girth.
(g) Bearing portion of drip course, bearing of moulding and cornice.
Note : In calculating area of an opening, any separate lintel or sills shall be included with the size of
the opening but end portions of lintel shall be excluded. Extra width of rebated reveals, if any, shall
also be excluded.
26.43.2.7.4 Walls 100 mm thick and less shall each be measured separately in square metres stating
thickness.
26.43.2.7.5 String courses, projecting pilasters, aprons, sills and other projections shall be fully
described and measured separately in running metres stating dimensions of each projection.
26.43.2.7.6 Square or rectangular pillars shall be measured separately in cubic metres in multiple of
100mm thick block wall.
26.43.2.7.7 Circular pillars shall be measured separately in cubic metres as per actual dimensions.
26.43.2.7.8 Block work curved on plan shall be measured like the block work in straight walls and
shall include all cutting and wastage of Blocks, tapered vertical joints and use of extra mortar, if any.
Block work curved on plan to a mean radius not exceeding six metres shall be measured separately
and extra shall be payable over the rates for Block work in straight walls. Nothing extra shall be
payable if the mean radius of the block work curved in plan exceeds six metres.
26.43.2.7.9 Tapered walls shall be measured net as walls and extra payment shall be allowed for
making tapered surface for block work in walls.
26.43.2.8 Rate
The rate shall include the cost of materials and labour required for all the operations described
above except the reinforcement and its encasement in cement mortar or cement concrete. The rate
shall also include the following:
(a) Raking out joints or finishing joints flush as the work proceeds;
(b) Preparing tops of existing walls and the like for raising further new Block work.
(c) Rough cutting and waste for forming gables, splays at eaves and the like.
(d) Leaving holes for pipes upto 150 mm dia. and encasing hold fasts etc.
(e) Rough cutting and waste for Block work curved in plan and for backing to stone or other
types of facing.
(f) Embedding in ends of beams, joists, slabs, lintels, sills, trusses etc.
(g) Bedding wall plates, lintels, sills, roof tiles, corrugated sheets, etc. in or on walls if not
covered in respective items and
(h) Leaving chases of section not exceeding 50 cm in girth or 350 sq cm in cross-section.
(i) Block on edge courses, cut Block corners, splays reveals, cavity walls, Block works curved
on plan to a mean radius exceeding six metres.

26.43.3 Block Work In Arches
Block work in arches shall be same as specified in clause 6.3.
26.43.4 100mm thick block work

Block work in 100 mm thick walls shall be done in the same manner as described above in 26.43.2.3
2 Nos. M.S. bars of 6 mm dia., shall be embedded in every third course as given in the item (the dia
of bars shall not exceed 8 mm). These shall be securely anchored at their end where the partitions
end. The free ends of the reinforcement shall be keyed into the mortar of the main block work to
which the 100 mm work is joined. The mortar used for reinforced block work shall be rich dense
cement mortar of mix 1:4 (1 cement: 4 coarse sand). Lime mortar shall not be used. Over laps in
reinforcement, if any shall not be less than 30 cm.
The mortar interposed between the reinforcement bars and the block shall not be less than 5
mm. The mortar covering in the direction of joints shall not be less than 15 mm.
The length and height of the wall shall be measured correct to a cm. The area shall be calculated
in sq.m. where 100 mm thick wall is joined to the main walls of 200mm or greater thickness and
measurements for 100 mm thick wall shall be taken for its clear length from the face of the thicker wall.
26.43.4.2 Rate
The rate includes the cost of the materials and labour involved in all the operations described
above except reinforcement which is to be paid for separately.
26.43.5 HONEY COMB BLOCK WORK

The honeycomb block work shall be done with specified class of block, laid in specified mortar. All
joints and edges shall be struck flush to give an even surface.
The thickness of the block honeycomb work shall be 100 mm thick only, unless otherwise specified.
Openings shall be equal and alternate with 100 mm thick block work laid with a bearing of 2 cm on
either side.
The length and height shall be measured correct to a cm. Area shall be calculated in square
metres correct to two places of decimal. Honeycomb openings shall not be deducted.
26.43.5.2 Rate
The rate includes the cost of materials and labour involved in all the operations described above.
26.43.6 Joining old block work with new block work
26.43.6.1 In case the height of the blocks of old as well as new work is same, the old work shall be
toothed to the full width of the new wall and to the depth of a quarter of block in alternate courses. In
case the height of the blocks is unequal, then the height of each course of new work shall be made
equal to the height of the old work by adjusting thickness of horizontal mortar joints in the new wall.
Where necessary, adjustment shall be made equal to thickness of old wall by adjusting the thickness
of vertical joints.
26.43.6.2 For joining new cross wall to old main walls, a number of rectangular recesses of width
equal to the thickness of cross wall, three courses in height and half a block in depth shall be cut in
the main walls. A space of the three courses shall be left between two consecutive recesses. The
new cross wall shall be bonded into the recesses to avoid any settlement.

26.43.6.3 Joining of old block work with the new brick work shall be done in such a way that there
shall not be any hump or projection at the joint.
The height and thickness of vertical face in contact with new work shall be measured to the
nearest 0.01 m and the area shall be calculated to the nearest 0.01 sqm.
26.43.6.5 Rate
The rate includes the cost of labour and material involved in all the operations described above.
26.43.7 Moulding and cornices

Shall be same as specified in 6.8
26.43.8 Exposed block work

Shall be same as specified in 6.10
26.43.9 Factory Made Cement Concrete interlocking Paver Block Made of C & D Waste
26.43.9.1 Base
Interlocking paver block to be fixed on the bed 50 mm or specified otherwise thick of coarse sand
of approved specification and filling the joints with the sand of approved type and quality or as
specified and as directed by Engineer-in-charge.
26.43.9.2 Interlocking Paver Block

Factory made cement concrete precast paver block of M-30 or otherwise specified grade to be
used. Paver blocks to be of approved brand and manufacturer and of approved quality. Paver blocks
shall be 60mm thick and made of C&D waste by block making machine with vibratory compaction.
Minimum strength as prescribed by manufacturer and as per direction of Engineer-in-Charge for the
grade specified to be tested as per method mentioned in specification of subhead cement concrete
of CPWD Specification 2019 Vol. I.
26.43.9.3 Measurement & Rates

Area provided with paver block to be measured in sqm. correct upto two places of decimal. The
rates include the cost of the material, labour, tools etc. required in all the operations described
above.
26.44 PRECAST TECHNOLOGY
26.44.1 General
26.44.1.0 Design criteria
26.44.1.1 Design criteria of precast RCC structural units shall conform to the Design requirements of
latest version of IS: 456.
26.44.1.2 Resistance to horizontal loading shall be provided by having appropriate moment and
shear resisting joints or placing the shear walls. Where shear walls are provided, rotational stiffness
of the floor wall joint is not to be considered.
26.44.1.3 Buttressing in the external walls shall be provided as external wall elements are not fully
restrained on both sides by floor panels and that external wall panel connections are the weakest
points in a precast panel structure.

26.44.1.4 In all load bearing elements, adequate restraint shall be provided at corners of the structure.
These elements and the external ends of cross wall units should be stiffened either by introducing
columns as connecting units or by joining them to non-structural wall units.
26.44.1.5 Bearing for Precast Units shall be as per clause 8.3 of IS 15916.
26.44.1.6 Slab panels shall be interconnected through joints at regular intervals to provide monolithic/
diaphragm action.
26.44.1.7 RCC decking/ topping reinforced screed shall be overlaid on precast panels for providing
rigid diaphragm action, under seismic conditions.
26.44.2. Joints:-
Requirements of a structural joint:
26.44.2.1. It shall be capable of being designed to transfer the imposed load and moments with a
known margin of safety.
26.44.2.2 It shall accept the loads without marked displacement or rotation and avoid high local
stresses.
26.44.2.3. It shall accommodate tolerances in elements.
26.44.2.4 It shall enable the structure to absorb sufficient energy during earthquakes so as to avoid
sudden failure of the structure.
26.44.2.5 Precast Components of the structure shall be designed for fire rating of two hours. Fire
rating for joints of the components shall be higher or at least equal to the fire rating of connecting
members.
26.44.2.6 The appearance of precast components joint shall merge with architectural aesthetic
appearance and shall not be physically prominent compared to other parts of structural components.
26.44.2.7 Precast structures may have continuous or hinged connections subject to providing sufficient
rigidity to withstand horizontal loading.
When only compressive forces are to be taken, hinged joints may be adopted. In case of
prefabricated concrete elements, load is transmitted via the concrete.
When both compressive force and bending moment are to be taken, rigid or welded joints may be
adopted. The shearing force is usually small in the column and can be taken up by the friction resistance
of the joint. Here load transmissions is accomplished by steel inserted parts together with concrete.
26.44.2.8. When considering thermal shrinkage and heat effects, provision of Expansion joints as
per IS 3414 shall be provided.
26.44.3 Load Testing:

26.44.3.1 Tests for Components/Structure:
Sampling Procedure: Lot for sampling shall be as per criteria laid down under clause 10.1.1 of IS
15916. The lot found satisfactory with respect to the dimensional requirements shall be tested for
load test. The lot shall be considered as conforming to the strength requirement, if all the units meet
the requirement; otherwise not.

Testing on Individual Components: Test load on the component, duration of applying the test
load, maximum deflection & recovery after removal of the test load & test observations shall satisfy
the requirements under clause 10.2 of IS 15916.
26.44.3.2 Test on completed structure:

Load testing on a completed structure or part of completed structure should be made, if there is
a reasonable doubt of adequacy in strength of the structure. The testing procedure on the structure
or part of completed structure as to the quantum of test load, duration of applying of the test load,
maximum deflection, and recovery after removal of the test load & other required test observations
shall be as per clause 10.3.1 of IS 15916.
26.44.4 Compliance with Design codes:

26.44.4 .1 Precast construction is to be undertaken broadly as per relevant BIS/ BS/ ACI codes and
standards for Precast constructions IS: 456, IS:15916, IS 15917, IS: 11447, IS: 10297 etc.
26.44.5 Manufacturing: The precast concrete elements shall be manufactured at an established

manufacturing facility in a factory with a quality controlled environment where a fully equipped quality
laboratory is made available.
26.44.6 Pre-tensioning Specifications:

The pre-tensioning of the precast elements, if resorted to, shall be accordance with the applicable
standards and the pre tensioning details of each typical element shall be submitted in advance for
approval from Engineer-in- Charge.
26.44.7.Specifications of the precast elements: The specifications for all the Precast concrete elements
should not be lower than the following:
(a) Grade of concrete: M40 min for precast & M50 min for pre-stressed.
(b) Reinforcing steel : Fe500D
(c) Prestressing steel :LRPS – FeP1860 – uncoated
(d) Cement – OPC 43/53 grade
(e) 2 hours fire rating for precast walls beams and slabs.
(f) Smooth finished surfaces for the precast elements
26.44.8.Product tolerances: All the pre-stressed precast concrete elements should be manufactured
in conformation to the tolerance limits as per the PCI manual.
26.44.9.Curing: The curing for precast/ and pre-stressed concrete elements should be as per the
applicable IS codes and supporting proof of curing records should be submitted.
26.44.10. Quality Assurance: The precast concrete elements should be tested in accordance with
the IS or ASTM standards including the following tests:
1. Slump tests.
2. Compressive Strength test
3. Typical element load bearing test
26.44.11 Transportation of precast elements: Since the construction is planned with precast technology
the precast concrete elements from the manufacturing location should not be removed and transported
until they attain at least 75% of the required compressive strength of 28 day duration.

26.44.12 Cranes for Erection: Cranes with at least 1.5 times safety margin along with calibration
certification only should be used for carrying out the erection of precast concrete elements at the
site.
26.44.13 Erection of Precast elements: The erection of the pre-stressed precast elements should be
done using experienced erection persons and as per the standard methodology and in safe manner
in accordance with design sequence ensuring erection tolerances as per the accepted Standards
(like PCI Manual).
26.44.13.1 for all precast/pre stressed elements irrespective of size, shape and thickness, should be
provided with proper lifting accessories for loading ,unloading and erection at site, nothing shall be
paid on account of this.
26.44.13.2 pre stressed elements should not be allowed to localized cutting after transporting to site
as pre stressed steel may get disturbed.
26.44.13.3 suitable openings should be provided for all precast/pre stressed elements for inserting
dowel bars ,passing the cables etc (Note: the size and shape of opening should as per relevant code
provisions.)
26.44.14 Connections: The precast elements should be given wet connections or alternatively as
per the design requirements. All the connection details and details of structural ties should be furnished
in advance for review and approval.
26.44.15 Grouting / Fillings: The grouting/fillings should be done with Premixed, packaged shrink-
resistant grout using materials of approved standards and technical specifications in accordance
with accepted grouting practices.
26.44.16 Screeding: The floor constructed with solid / hollow core precast slabs should be covered
with concrete screed of required thickness using the same grade as that of precast member and by
providing reinforcement for integrating with adjacent precast components and to obtain the monolithic
behavior to slab .However the change in grade of concrete from that of base precast members may
be accepted depending upon the designer recommendations duly approved and based on the site
conditions wherever it so warranted
26.44.17 Joint Fillings: The joints of the constructed precast elements should be filled with backer
rods and weather proof mastic sealants using standard materials and as per the approved
methodology.
26.44.18 Mock-up of precast elements: If required, the contractor should demonstrate mock-up of
precast elements and their erection in advance for observation and approval.
26.44.19 Methodology Statements: Methodology statements for manufacturing of precast elements,

transportation, erection, connection, and screeding should be submitted in advance for approval.
The methodology statements for safety practices should also be submitted.
26.44.20 Testing of the Structure: After construction of the structure, the part of it should be loaded
with 1.5 times the design load for deflections and other parameters.
26.44.21 Components of RCC structure shall be designed for loads in accordance with IS 875
(Parts l to 5) and IS 1893-Part 1. In addition, loads that might be expected during the construction
shall also be considered in the design.

26.44.22 The pre-cast RCC manufacturing unit of pre cast elements shall be got approved from
Engineer-in-charge before start of work.
26.44.22.1 The pre-cast manufacturing unit shall have minimum capacity of 45 cum/hour fully automatic
batching plant and having manufacturing capacity of 300sqm/day of prestressed precast hollow core
slab & 50 cum/day of solid pre-cast element.
26.44.22.2 The manufacturing unit of pre cast elements shall be within feasible distance from site so
that quality of pre cast elements can be inspected by Engineer-in-charge or his representatives
during casting.
26.44.22.3 The contractor shall at his own expenses furnish all stakes, templates, platforms, equipment,
arrange labour that may be required in setting or laying out any part or which of the work. The
contractor shall be held responsible for proper execution of the work to such lines and grades as
may be established or indicated in the drawings and specifications.
26.44.22.4 Pre-cast concrete construction (RCC Columns and Hollow core slabs)
(a) The concrete mix used shall be of min of M-40 grade Ready mix concrete for solid precast
elements viz. columns and footings and M-50 grade Ready mix concrete for prestressed
hollow core slabs of required size and thickness in accordance with IS:1343
(b) The prestressing of steel strands for manufacture of hollow core slabs shall be done in
accordance to the IS: 1343.
(c) Hollow core slabs shall be provided with suitable weep holes wherever necessary
(d) Contractor shall provide suitable steel shuttering moulds as per drawing to cast the RCC
columns with the specified dimensions and tolerances in factory approved by Engineer-in-
charge.
(e) Reinforcement shall be fabricated to the required shape & size and put in the mould as per
drawings. Embedded parts, hooks if any shall be placed, anchored properly and aligned as
per requirements for which no extra payment shall be made.
(f) Hollow core slab manufacturing details as per the manufacturer’s recommendations satisfying
the design intents showing the details of HTS wires, stressing etc shall be submitted prior to
actual manufacturing.
(g) Concrete of specified grade as per the design shown in drawing shall be poured into the
form work, compacted and finished to final shape. All the pre-cast elements shall then be
sufficiently cured by steam curing method under strict supervision of Engineer-in-charge
or his authorized representatives.
(h) Contractor shall transport the elements columns & footings to the site of the work / location
and shall place in position by mechanically operated mobile cranes.
(i) Contractor shall be responsible for proper handling of the units and will ensure regular
supply of precast RCC elements.
(j) Temporary Openings shall be provided at the base of columns and wall of its form work and
other places necessary to facilitate cleaning and inspection.
(k) Immediately before concrete is placed, all forms shall be carefully inspected to ensure that
they are properly placed, sufficiently rigid and tight, thoroughly cleaned, properly treated
and free from foreign materials before they are again used. If forms appear to be
unsatisfactory in any way either before or during the placing of concrete, the Engineer-in-
charge shall have power to stop the work until the defects are corrected.

26.44.22.5 Transportation and Erection of Pre-cast elements:
(a) Necessary lifting hooks/holes shall be provided at structurally advantageous points to facilitate
demoulding and erection of precast units in accordance with IS: 10297
(b) All the pre cast elements from the manufacturing unit shall be transported by suitable trailer in
such a way that pre cast elements are not damaged in during transit.
(c) Contractor shall ensure that all the corners/edges are properly protected during transportation.
(d) Damaged elements shall not be allowed to use in the works.
(e) It shall be ensured that clearance of Engineer-in-charge is obtained prior to erection.
(f) Erection of all pre cast elements shall be done by telescopic crane of suitable capacity with skilled
man power.
(g) Initially pre cast columns are to be erected in the designated locations to the required level,
dimensions and tolerances as per lay out of the approved execution drawing after placement of
leveling course of concrete.
(h) After successful erection of series of columns in a particular stretch, the intermediate panels are to
be erected in between the columns by cranes.
(i) Panels are to be erected vertically without any offsets and suitable rubber packers approved by
Engineer-in-charge, shall be provided where ever required for erection purpose for which no extra
payment shall be made.
26.44.23 Documentations: All stages of manufacturers of precast element, i/c prestressing, testing & checking
transportation, checking again at site, laying/erection at site, testing etc. shall be documented by the agency
and shall be submitted to Engineer-in-charge before passing of final bill.
26.44.24 Fabrication & Manufacturing of Prestressed Hollow Core slab (Hollow area 25 to 30%) of different
thickness & modular width 1200 mm in Controlled Factory Environment with approved methodology, conforming
to IS:10297 by using long line casting method having arrangement of proper steel bed.
Concreting should be done by batch mixing plant capable of producing zero slump concrete, transported
through automatic shuttels of standard make & laid on bed with the help of extruder/Slip former, finishing, curing
and also provision of steam curing. Cutting, making necessary cutout/holes of required sizes for services in slab
element after achieving required strength, yard handling & stacking all complete as per approved shop drawings &
design mix as per the direction of the Engineer-in-charge.
Note: Less cement used than the specified cement content as per design mix is recoverable. However,
nothing extra shall be paid for excess use of cement than the specified. 3.9.1 Concrete Grade M-40 (Cement
content 400kg)
26.44.25. Fabrication and manufacturing of solid precast concrete element with provisions of shear keys,
connecting loops, dowel tubes and proper lifting accessories for walls, beams, slabs, stairs, column etc, of
various thickness, shape and size of different concrete grades manufactured in controlled factory environment
with approved methodology including moulds (Pallet system, Tilts form, table moulds, battery moulds, vertical
moulds, beam moulds, column moulds, staircase moulds, Facade mould, etc,), mixing, transporting and
placing of concrete, vibrating, curing, finishing, making necessary cutout/holes of required sizes for services,
yard handling & stacking all complete as per IS 11447 and as per approved shop drawings and design mix as
per the direction of Engineer-in-Charge. (Cost of reinforcement, Mechanical, Electrical and Plumbing inserts
will be paid separately).
Note: Less cement used than the specified cement content as per design mix is recoverable. However,
nothing extra shall be paid for excess use of cement than the specified.

26.44.26. Transportation of Precast Elements by flat bed Trailor (Double / Triple axle 40ft Length
with proper accessories like A frame etc) from factory, including the cost of loading, unloading &
stacking at site with the help of required capacity cranes.
26.44.27 Erection & Installation of Precast/Prestressed Concrete elements in correct & final position
with proper line level and plumb at site making all arrangements (i.e. cranes, push-pull jacks & all
another T & P for lifting Placing & Alignment of elements, within erection tolerance as per IS 15916 as
per approved shop drawings and all complete as per the direction of Engineer-in-Charge but excluding
the cost of simpads, non shrink grout and steel works i.e hangers.
Pre-stressing wires shall confirm to IS: 14268.

RCC in column, Beams, stairs& slabs – all precast members
(i) Precast external insulated wall panels, 185mm thick with M40 & Fe 500D.
(ii) Precast internal wall panels, 125mm thick with M40 & Fe 500D.
(iii) Precast parapet wall panels, 185mm thick with M40 & Fe 500D.
(iv) Precast beams with M40 & Fe 500D/or prestressed with M50 & prestress steel Fe P1860
(v) Precast solid slabs, 150mm thick with M40 & Fe 500D/ or prestressed with M50 & prestress
steel Fe P1860
(vi) Precast staircase (150mm riser and 300mm tread width) M40 & Fe 500D or prestressed
with M50 & prestress steel Fe P1860
(vii) Precast solid slabs for ramps, 150mm thick with M40 & Fe 500D or prestressed with M50 &
prestress steel Fe P1860
(viii) Precast columns with M50 & Fe 500D
Pre-cast reinforced concrete units shall be of grade or mix as specified. Provision shall be made
in the mould to accommodate fixing devices such as hooks etc. and forming of notches and holes.
Each unit shall be cast in one operation. A sample of the unit shall be got approved from Engineer-in-
charge before taking up the work.
Pre-cast units shall be clearly marked to indicate the top of member and its location.
Pre-cast units shall be stored, transported and placed in position in such a manner that these
are not damaged.
The compaction of the concrete shall be done by vibrating, table or external vibrator, as approved
by Engineer-in-charge. The rates include the element for framework and mechanical vibration.
26.44.28 Measurement: Dimensions shall be measured nearest to a 0.50 cm The areas shall be
worked out nearest to 0.01 Sq. mt. The cubical contents shall be worked out to nearest 0.01 cubic
metre.
26.44.29 Rate
The rate for item includes cost of all materials. labour, and all operations involved. Cost of M.S.
frames, lugs including their welding, lifting hooks is also included.
In the item of providing and fixing precast reinforced cement concrete in shelves the cost of cutting
chases and making good the same shall be inclusive in the item and nothing extra shall be paid on
this account.

26.45 SCAFFOLDING NET
26.45.1 Scaffolding net of required width made of high density Polyethylene UV stabilized knitted on
warp knitting machines having density 100gm/sqm and shading coefficient minimum 75% around the
construction site/ for vertical extension as per requirement including fastening/tying with building/
scaffolding pipes or with any other fixtures etc. should be used.
26.45.2 Net shall be made with a square or diamond mesh. Maximum size of opening shall not
exceed 10X10 mm. A continuous length of net having no joints, shall be used to cover the span
between the supports. When in use, the net shall have a sag at the centre of not less than one-fifth
and preferably not more than one-fourth of the length of the shorter side. The ends of all cords used
in the nets shall be secured to prevent unraveling. The maximum vertical distance between the
working level and the level at which the safety net is to be used shall be such that it should not
hamper the progress of the work or should not make inconvenience to the work force. The work shall
be carried out as per IS-11057
26.45.3 Measurement: One time measurement will be given in square meters for throughout
completion of the project including extended time, if any, as per various clauses and per direction of
Engineer- in- Charge.
26.45.4 Rate:
Onetime payment shall be made for providing Scaffolding net from start of work till completion of
work including shifting if any. The Scaffolding net shall be the property of the contractor on completion
of the work

BAMBOO MAT CORRUGATED SHEET (BMCS)
Sub Head : 26. New Technologies and Materials

Clause : 26.7.2
Fig. 26.1
Fig 26.2 End lap of BMCS
CROWN- 09 Nos
VALLEY -08 Nos
Fig. 26.3 Details of Corrugation
Sub Head : 26. New Technologies and Materials

Clause : 26.7.2

CORRUGATION LAP 1100 MM
Fig .26.4 Side lap of BMCS
Fig No.26.5
Fig. 26.6

Sub Head : 26. New Technologies and

Materials
Clause : 26.7.2
Fig. 26.7 BMRC Ridge purlin
Cavity wall thermal insulation system with rigid foam insulation

Sub Head : 26. New Technologies
and Materials
Clause : 26.11.3
Fig. 26.8 ĂǀŝƚǇǁĂůůƚŚĞƌŵĂůŝŶƐƵůĂƚŝŽŶƐǇƐƚĞŵǁŝƚŚƌŝŐŝĚĨŽĂŵŝŶƐƵůĂƚŝŽŶ

Under Deck insulation system

and Materials
Clause : 26.12.3
Fig. 26.9 Location of Fasteners of extruded Polystyrene Rigid Underdeck insulation.

GEOGRIDS
and Materials
Clause : 26.14.1
ALUMINUM PROFILE INDUSTRIAL TROUGHED SHEET - SELF-

DRILLING FASTENERS
and Materials
Clause : 26.15.3

GALVA
VANIZED STEEL DECK SHEET
and Mat
aterials
Clause : 26.42.1
.1.1
26.14 Galvanized Steel Deck Sheet

Fig 2

SHEAR CONNECTORS
and Mat
aterials
Clause : 26.42.1
.1.2
Fig 26.15 A
Fig 26.15 B Fig

g 26.15 C
Fig 26.15 Shear Connectors

ECO FRIENDLY LIGHT WEIGHT CALCIUM SILICATE FALSE CEILING (MICRO LOOK EDGE)

and Materials
Clause : 26.17
Fig . 16 Eco Friendly Light Weight Calcium Silicate False Ceiling (Micro Look Edge)

ECO FRIENDLY LIGHT WEIGHT CALCIUM SILICATE WALL PANELLING (FULLY
PERFORATED SQUARE/ BUTT EDGED)

and Materials
Clause : 26.18
Drawing of wall panel/frame
Fig 17. Eco friendly light weight calcium silicate wall paneling (fully perforated square/ butt
edged)

Specs 2019 V2

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Specs 2019 V2

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GOVERNMENT OF INDIA

CENTRAL PUBLIC WORKS DEPARTMENT

Published under the Authority of Director General, CPWD, New Delhi

A GOVERNMENT OF INDIA PUBLICATION

Printed & Distributed by

JAIN BOOK AGENCY JAIN BOOK DEPOT

JAIN BOOK AGENCY (SOUTHEND) JAIN BOOK AGENCY (GURGAON)

JAIN BOOK AGENCY (INTERNATIONAL) JAIN BOOK AGENCY (GREATER NOIDA)

The CPWD Specifications were first compiled in 1950. Subsequently, these

The revised/updated specifications are being published in two volumes.

I am sure that these Specifications will be useful to all concerned in the

2.0 CPWD Specifications, 2019 is published in two volumes as under:

Volume Sub-head No. Contents/ Chapters

6.0 Sub-head wise salient features are as follows:

Suggestions for improvement are welcome.

13.0 FINISHING 625 – 680

14.0 REPAIRS TO BUILDINGS 681 – 730

15.0 DISMANTALING AND DEMOLISHING 731 – 744

16.0 ROAD WORK 745 – 876

17.0 SANITARY INSTALLATIONS 877 – 940

18.0 WATER SUPPLY 941 – 1008

19.0 DRAINAGE 1009 – 1074

20.0 PILE WORK 1075 – 1118

21.0 ALUMINIUM WORK 1119 – 1158

22.0 WATER PROOFING TREATMENT 1159 – 1206

23.0 RAIN WATER HARVESTING & TUBEWELLS 1207 – 1240

24.0 CONSERVATION OF HERITAGE BUILDINGS 1241 – 1256

25.0 STRUCTURAL GLAZING ALUMINIUM COMPOSITE PANEL 1257 – 1274

26.0 NEW TECHNOLOGIES AND MATERIALS 1275 – 1368

For Sub Heads 0.0 to 0.12 see Vol. 1.

Clause No. Brief Description Page No.

List of Bureau of Indian Standards Codes 631

13.1 Cement Plaster 12 mm, 15 mm, or 20 mm 633

13.2 Cement Plaster with a Floating Coat of Neat Cement 636

13.3 18 mm Cement Plaster (Two Coat Work) 636

13.4 6 mm Cement Plaster on Cement Concrete and 636

13.5 6 mm Cement Plaster for Slab Bearing 638

13.6 Neat Cement Punning 638

13.7 Rough Cast Plaster 639

13.8 Pebble Dash Finish (In Situ Work) 640

13.9 Plain Bands of Cement Mortar 640

13.10 Moulded Bands of Cement Mortar (Single Coat Work) 641

13.11 Moulded Bands of Cement Mortar (Two Coat Work) 641

13.12 Cement Water Proofing Compound 642

13.13A White cement based polymer modified mortar 645

13.14 White Washing with Lime 646

13.15 Satna Lime Washing 647

13.16 White Washing with Whiting 647

13.17 Colour Washing 648

13.18 Dry Distempering 648

13.19 Oil Emulsion (Oil Bound) Washable Distempering 649

627 SUB HEAD 13.0 : FINISHING

13.20 Cement Primer Coat 652

13.21 Cement Paint 652

13.22 Exterior Painting on Wall 653

13.23 Painting 655

13.24 Painting Priming Coat on Wood, Iron or Plastered 659

13.24A Epoxy Paint 661

13.25 Painting Synthetic Enamel Paint over G.S. Sheets 662

13.27 Painting with Wood Preservative 663

13.27A Fire Retardant Paint 664

13.28 Coal Tarring 664

13.31 Wall Painting with Plastic Emulsion Paint 666